Lightweight audio system for automotive applications and method

ABSTRACT

A lightweight radio/CD player for vehicular application is virtually “fastenerless” and includes a case and frontal interface formed of polymer based material that is molded to provide details to accept audio devices such as playback mechanisms (if desired) and radio receivers, as well as the circuit boards required for electrical control and display. The case and frontal interface are of composite structure, including an insert molded electrically conductive wire mesh screen that has been pre-formed to contour with the molding operation. The wire mesh provides EMC, RFI, BCI and ESD shielding and grounding of the circuit boards via exposed wire mesh pads and adjacent ground clips. The PCB architecture is bifurcated into a first board carrying common circuit components in a surface mount configuration suitable for high volume production, and a second board carrying application specific circuit components in a wave soldered stick mount configuration. The major components and subassemblies are self-fixturing during the final assembly process, eliminating the need for dedicated tools, fixtures and assembly equipment. The major components and subassemblies self-interconnect by integral guide and connection features effecting “slide lock” and “snap lock” self-interconnection. The radio architecture includes improved push buttons employing 4-bar living hinge linkage and front loaded decorative trim buttons.

RELATED APPLICATIONS

This is a divisional application of U.S. Ser. No. 11/893,357, filed 15Aug. 2007, which claims the benefit of U.S. Ser. No. 60/838,698 filed 18Aug. 2006 to Chris R. Snider et al., entitled Lightweight AutomotiveRadio/CD Player and U.S. Ser. No. 60/931,467 filed 23 May 2007 to ChrisR. Snider et al., entitled Lightweight Automotive Telematic Device, bothassigned to a common assignee.

TECHNICAL FIELD

The present invention relates generally to apparatus for enclosingelectrical subassemblies, and more specifically relates to apparatus forefficiently securing subassemblies to a chassis of an electricalassembly such as an automobile radio, compact disc playing mechanism,cassette tape playing mechanism, navigational aid, personal computer,personal and telematic communication devices or disk drive mechanism.

BACKGROUND OF THE INVENTION

Devices such as automobile radios or personal computers containsubassemblies such as cassette playing mechanisms or disk drives thatare attached to the chassis using threaded fasteners. The chassisprovides structural support for the subassemblies and also provideselectromagnetic shielding to limit electromagnetic interference (EMI)experienced by, and/or created by the device. The fasteners ensure thateach subassembly within the chassis is properly located and securelyretained within the chassis.

The use of such fasteners can have numerous drawbacks, particularly in ahigh volume production setting. The process for applying or installingfasteners can vary, but there is usually some degree of automationrequired, ranging from manually loading a screw into a bit on apneumatic driver to using self-feeding automated machines. Typically,the torque applied by the device used to drive the fasteners must bemonitored regularly and adjusted in order to assure proper seating ofthe fasteners. When fasteners are used, sheet metal tolerances, as wellas tolerances of the fasteners themselves, have to be maintained attight levels to allow for the minimization of stress in the assemblywhen aligning multiple fasteners with corresponding holes in the chassisand in the subassembly.

When threaded fasteners are used to assemble an electrical device, theassembly cycle time can be very long especially in high volumeproduction. An operator assembling the device must typically firstobtain the threaded fastener, orient and position it in alignment withthe driver bit, then manipulate or actuate the machine to drive thethreaded fastener. Furthermore, using threaded fasteners presents a riskof any one of the following upstream failures occurring: stripping offastener threads; insufficient torque resulting in an unseated fastener;excessive torque resulting in distension/deformation of the fastener oradjacent electrical components; installation of the wrong fastener typeor size; foreign object damage due to fasteners and/or metal shavingsdropping onto the assembly and/or subassembly; and stripping of the headof the threaded fastener. Also, a fastener installation tool such as adriver and bit can slip off the fastener and impact an electricalcomponent resulting in a damaged assembly.

If self-tapping fasteners are used, the process of driving theself-tapping fasteners into sheet metal often causes shavings of sheetmetal to disperse into the assembly. Such shavings have been known tocause electrical failures, such as shorts or corruption of magneticcomponents that can permanently damage the product. If self-tappingfasteners are not used, an extra production step is required to pre-formthreads in the sheet metal of the chassis and/or the subassembly to beinstalled within the chassis.

Fasteners further require an additional inventory burden on theproduction line in that the production line must be continuously stockedwith part numbers (fasteners) other than the integral components thatadd value to the assembly. Also special tools specifically required forassembly, using fasteners, such as drivers and bits, must becontinuously monitored and maintained for proper performance, wear andtorque specifications. Typically, the top and/or bottom surface of thechassis must be secured in place after the subassembly is attached tothe chassis.

Special fixtures are often required on the production line to secure asubassembly in a proper location and orientation while it is mountedwithin the chassis with fasteners. Such fixtures can be very complex,and the use of such fixtures usually requires extra handling of both thesubassembly and of the resulting assembly thereby adding to theproduction cycle time and potentially compromising quality of the finalproduct.

FIG. 1 illustrates the construction of a typical prior art automotiveradio/compact disc (CD) player 10. Radio/CD player 10 comprises a radiosubassembly whose principle circuit components are carried on a circuitboard 12 and a CD player subassembly 14. The circuit board 12 and the CDplayer 14 are encased within a common chassis 16 made up of sheet metalcomponents. Chassis 16 includes a wraparound housing 18 defining a backand sidewalls, a top cover 20, a bottom cover 22 and a front plate 24which are interconnected by numerous threaded fasteners to collectivelyenclose the subassemblies. The top and bottom covers 20 and 22,respectively, are provided with large arrays holes or openings forairflow and ventilation of heat generated within the radio/CD player 10.A convector or heat sink 26 is carried on an outer surface of one of thechassis sidewalls and is interconnected through a port/window 28 to apower device assembly 30. A trim plate assembly 32, along with a supportpad 34 and CD dust cover 36 are affixed to the front plate 24, providingan operator control interface with the radio/CD player 10. Circuit board12 is electrically in-circuit with the CD player subassembly 14 throughan intermediate flex wire cable 38 and with the power device assembly 30through a jumper cable 40. Information bearing labels 42 and 44 areprovided for future reference by the operator and service technicians.The radio/CD player 10 is electrically interconnected with an antenna,power supply, speakers and other related systems of a host vehicle byrear-facing connectors 46 carried on the circuit board 12 which areregistered with openings 48 in the rear wall of wraparound housing 18.The radio/CD player 10 is mounted within a host vehicle by threadedfasteners passing through openings in mounting features 50 extendingfrom front plate 24 and a rearwardly directed mounting bushing 52 whichis threadably affixed to a stud 54 carried on the outer surface of therear wall 56 of wraparound housing 18. As best seen in FIGS. 11 and 12,the shank of the stud 54 extends outwardly through a hole 58 disposedconcentrically with a localized recess 60 and the stud 54 is seatedwithin the recess 60. FIG. 90 illustrates another known stud designincluding a threaded shank secured to the rear wall 53 of a radio set 51by a set nut 55 and receiving a molded rubber, plastic or vinyl stud 57thereover. Note the large number of threaded fasteners 59.

The radio/CD player 10 of FIG. 1 is of ordinary complexity and mayrequire fifty or more threaded fasteners to complete the manufacturingprocess. Installation of that many fasteners may require that thein-process chassis be re-positioned/re-fixtured ten to fifteen times asit passes along an assembly line of eight to ten skilled workers/workstations.

Vehicle entertainment systems usually include an audio component such asa radio to enable receiving signals from antennas, contain various formsof playback mechanisms, and have the capacity to accept data from userdevices like MP3 players. Typically, the radio has a decorative assemblythat provides man-machine interface as well as displaying pertinent datarelative to the selected media and audio settings. Also, the back-end orchassis is constructed of metal to provide various functions to ensurethe performance of the radio in the vehicular environment. The structureto contain the mass from playbacks, the heat conductive properties, andthe electrical shielding and grounding are just a few of the advantagesto using the metal construction. Unfortunately, with the density of themetal, the disadvantage of added weight is a side effect of the typicalconstruction. In a vehicle, added weight impacts fuel economy, as wellas other hidden costs during assembly that can effect the cost of theproduct, like sharp edges of metal can be a potential hazard forassemblers in the manufacturing plant as well as added weight can limitthe packaging of multiple parts in containers for inter and outer plantdistribution.

Thermal Management System

Devices such as automobile stereos, audio amplifiers, home stereosystems, two-way radios, computers, signal conditioners/amplifiers,compact disc playing mechanisms, and cassette tape playing mechanismsare examples of products that typically require electrical components toamplify signals and regulate power. Accordingly, such devices typicallycontain numerous electrical components such as single in-line package(SIP) amplifiers and regulators that are typically soldered into printedcircuit boards. Such electrical components generate heat in use. Theheat must be dissipated away from the electrical components to avoiddamage that can be caused by excessive temperatures in the electricalcomponents. For example, excessive temperatures can cause delicateelectrical leads to fail or insulating materials to melt, therebycausing a short circuit resulting in damage to, or even failure of, theentire electrical device.

A convector is often mounted to an outer surface of such a device todissipate heat generated by components by transferring the heat awayfrom the components and the device to the convector and then to the airthrough radiation. In order to accomplish this, it is preferable thatthe convector be physically in contact with the component. Thecomponents and the convector can be pressed together to allow evenbetter heat conduction from the components to the convector. Sometimesan intermediary material such as a thermal pad or silicon grease is usedbetween the component and the convector to assist in creating anadequate heat transfer junction.

Many convectors are made from aluminum due to the high heat conductivityof that material. Convectors often include a plurality of fins toincrease the effective surface area of the convector and therebyincrease the rate at which the convector can dissipate heat. Typically,aluminum, convectors are formed by an extruding process, during whichthe fins can also be formed integrally therewith.

Convectors are usually assembled to the component or components duringfinal assembly of the overall device in which they are used. At finalassembly, components such as SIP amplifiers are already soldered into aprinted circuit board. The order of assembly can vary as to whichcomponent is assembled into the chassis first. The printed circuit boardcan be installed into the chassis before the convector is mounted to theprinted circuit board and the chassis. Alternatively, the convector canbe mounted to the chassis before the printed circuit board is mounted tothe convector. Sometimes, the convector is assembled to the printedcircuit board to form a subassembly before being assembled to thechassis.

Typically, components are attached to the convector using a clip and oneor more threaded fasteners that extend through a hole in the clip andinto a hole in the convector. The clip, component and convector must allbe simultaneously held in a fixture and then be fastened together with athreaded fastener. If the component includes a hole to accept a threadedfastener, it can be mounted directly to the convector using a threadedfastener that extends through that hole, without using a clip.

The use of such fasteners can have numerous drawbacks, particularly in ahigh volume production setting. Often, each hole in the convector thatreceives a fastener must be separately drilled or punched. This isespecially true for an extruded convector if the axis of the hole is notaligned with the direction in which the convector is extruded. Thefastening process can vary, but there is usually some degree ofautomation required, ranging from manually loading a screw into a bit ona pneumatically or electrically powered driver to using self-feedingscrew machines. Typically, the torque applied by the device must bemonitored regularly and adjusted in order to assure proper seating ofthe fasteners.

The clamping force between the convector and the component should be ata proper level to ensure sufficient heat transfer to the convector. Whenfasteners are used to attach the convector to the component, clampingforce is a function of the type of fastener and its condition and degreeof assembly (e.g. the level of torque applied during installation of thefastener). Thus, a threaded fastener that is not seated all the way willgive less clamping force than one that is seated all the way. Or, astripped or improper type of fastener may provide an insufficientclamping force.

Special fixturing is often required to hold a component in the properlocation while it is mounted to the convector using one or morefasteners. Such fixturing can be very complex and use of such fixturingusually requires extra handling of both the component and of theresulting assembly, thereby adding to the production cycle time andpotentially compromising quality of the final product.

When threaded fasteners are used, the assembly cycle time can be verylong, especially in high volume production. The operator mustspecifically obtain the threaded fastener, bring it in contact with thedriver bit, then drive the threaded fastened. If self-tapping fastenersare used, the process of driving the self-tapping fasteners into metaloften causes metal shavings to disperse into the assembly. Such shavingshave been known to cause electrical failures that can permanently damagethe product. If self-tapping fasteners are not used, an extra productionstep is necessary to form threads in the metal of the convector.

Accordingly, there is a need for electrical assemblies that do notrequire fasteners or tooling for securing a component to a convector.

Electrostatic Discharge Device

Static electricity (electrostatics) is created when two objects havingunbalanced charges touch one another, causing the unbalanced charge totransfer between the two objects. This phenomenon commonly occurs inhomes, vehicles and other environments when the air is dry (i.e. has acharacteristic relatively low level of humidity). For instance, when aperson slides onto a car seat, electrons may transfer between the two,causing the surface of the person's body to store a charge. When theperson, then, touches a vehicle component, the charge may travel(discharge) from the body to the component, thus creating staticelectricity. If the object touched is an electronic device, such as ahome stereo, home theatre system, computer, vehicle entertainment systemor other electronic media system, this electrostatic discharge can beharmful to the sensitive electronic components of the device. Forinstance, when a person slides onto a vehicle seat and inserts a discinto the car stereo, a charge may travel from the body through the discto the sensitive electronic components in the vehicle stereo. Similarproblems may occur when using DVD and other magnetic media and discplayers.

Accordingly, problems with the drainage of a static electric chargeimpacting sensitive electronic components continue to persist.

Living Hinge Button Switch Linkage

A variety of automotive accessories, e.g., an automotive radio, within amotor vehicle employ button switches. Traditionally, buttons for thebutton switches have been fabricated and decorated (i.e., painted andlaser trimmed) individually. The buttons are then set in a separatehousing that includes a plurality of integrally formed guides foraccepting the buttons. Unfortunately, each of the buttons has requiredindividual fabrication and decoration, which significantly increases thetotal cost of an end product so designed. Further, as the individualbuttons are actuated, they can produce a squeaking noise due to the factthat each of the individual buttons includes a number of posts that matewith integrally formed guides in the housing. Various automotiveaccessories, such as an automotive radio, also receive inputs fromrocker switches, which, similar to button switches, have been paintedand laser trimmed and also may create noise when a user actuates therocker switch as the switch may engage a separate housing or trim plate.Additionally, both button and rocker switches have generally requiredadditional components (e.g., springs) to provide a desired tactile feel.

Thus, what is needed is a parallel guide mechanism for a switch thatprovides noiseless actuation and guided movement and allows for materialand/or component design that provides a desired actuation tactile feelwithout increased component cost.

Integrated Vehicle Display Lighting Assembly

Vehicle display assemblies often use a backlit liquid crystal display(LCD) so that the display can be viewed easily by the user. Fluorescentlight is the most common backlight source for LCDs. To ensure that thedisplay can be read in daytime ambient light, the display backlightingis relatively intense.

The display assemblies may also include buttons for operating, forexample, a radio or a CD player. Current assemblies illuminate eachbutton with its own incandescent light source, providing backlightingand color for any graphics on the button. Each light source may includea colored boot to produce a desired light color for the button graphics.

As vehicles incorporate more features that require more buttons, thenumber of light sources also increases. The heat generated from theincandescent lights, however, elevates the temperature of the buttons byas much as 20° C., enough to be noticeable by a user. Further, theincreased temperature may place undesirable thermal stress on thedisplay components. Thermal protection algorithms may be used to monitorthe assembly temperature and reduce the light intensity if thetemperature reaches a selected threshold until the temperature drops toan acceptable level. Unfortunately, these systems require additional,cumbersome circuitry for turning the button light sources on and off.

There is a need for a display assembly lighting system that canilluminate a main display and adjacent buttons while keeping theassembly temperature within a desirable range.

It is known in the art that illuminated display systems, such as thosefound in radio receivers, compact discs, and heating, ventilation, andair conditioning (HVAC) controllers, include a back-lit display panel.Typically, it has been common practice to locate light pipes between aprinted circuit board and the display panel to direct light from a lightsource to a portion of the display panel for controlled illumination.However, because this location of the light pipe is typically shared byother electrical components and mechanical structures (i.e. buttonbodies, potentiometers, plastic ribs, LCD displays, etc.), the design ofthe light pipe may become complex, which may affect the efficiency ofthe lighting system.

Accordingly, a final design of the light pipe has often included complexstructures that weave between the electrical components and mechanicalstructure. Once light is provided to an entrance port of the light pipe,gradual changes in direction of light propagation by means of totalinternal reflection on non-parallel light pipe walls tend to introducelosses as collimation decreases. Losses in collimation also increase thedifficulty in directing light exiting the light pipe to the specificareas of the display panel.

The complexity of such light pipe designs makes computer simulationdifficult and time consuming, which lends to prevention of designoptimization by means of iterative prototyping and expensive designcycles drawn out with proof of concept often being delayed untilinjection molded light pipe prototypes can be produced. As such, a needexists for improving the collimation effects and efficiency of lightpipes applied in an illuminated display system.

Self-Aligned Button Retainer

There are numerous types of switch mechanisms in use today for operatingand regulating systems and components of vehicles and other devices. Theswitch mechanisms can be on-off type switches, switch mechanisms whichregulate the volume, amplitude and/or intensity of various systems,switch mechanisms which are available only for emergency-type usage, andthe like.

In automobiles and other vehicles, there are numerous types of switchmechanisms which are used for the various electronic components andsystems that are available and in use in the vehicles. These electroniccomponents include windshield wipers, emergency lights, turn signals,cruise control, power seats, power windows, heated seats, four-wheeldrive systems, overdrive systems, navigation systems, timing systems,clocks, mileage, trip or travel systems, and the like. Many of thesemechanisms have dual functions, such as being used not only to control,for example, the on-off status of the component or system, but also toadjust one of its functions, such as amplitude, balance, base, treble,etc. Many such switches utilize rocker-type buttons which pivot orrotate around a central point or section and have two ends which areadapted to operate or actuate certain switches or systems. Automotiveentertainment systems such as radios and CD players frequently use pushbutton type switches in space-saving compact arrays, with packagingspace being a premium.

Switch mechanisms are typically designed to meet various criteria andconsiderations other than function. The considerations includeappearance, aesthetics, ease of assembly, positioning, ease of use,versatility of function, and design. These considerations can affect thesize, color, type, and method of activation of the switch mechanism. Theswitch mechanisms are also made from various types of materials,including plastic, acrylic, and metal materials. In this regard, costand durability factors can be significant in the final selection of theswitch mechanisms to be utilized.

Although there are numerous switch mechanisms in use today which operatesatisfactorily, there is a constant need to improve the operation,versatility and appearance of various switches, as well as to correctproblems with existing switches. For example some of the switchmechanisms provide excess freedom of movement, have undesirable noiseproblems, are too expensive, have alignment problems in the socket orhousing in which they are positioned, do not operate with the requisitetactile “feel”, or are simply too difficult to operate for the desiredfunction. Thus, a need exists for improved switch mechanisms,particularly those which minimize noise problems, have improvedalignment, have the desired “feel” or can be adjusted to achieve thedesired feel, and which can be easily and simply actuated.

Interface with Personal Entertainment Devices

Vehicle entertainment systems usually include an audio component such asa radio to enable receiving signals from antennas, contain various formsof playback mechanisms, and have the capability to accept data from userdevices such as MP3 players. Typically, the radio has a decorativeassembly that provides man-machine interface as well as displayingpertinent data relative to the selected media and audio settings.

Many consumer electronic devices like the popular iPod from MacIntoshhave become mainstream must-haves for certain demographic groups ofconsumers. Automobile manufacturers are developing methods to allow theconsumer to connect to the automobile's entertainment system with theirpersonal music device, whether it be an iPod, a memory stick via a USBport, or a similar device. Several automobile manufacturers such as BMWand VW/Audi have provided a pig-tail or wired connection for an iPod intheir glove box.

Referring to FIG. 127, alternative prior art approaches are illustratedwherein a personal device is directly interconnected with the vehicleentertainment system through a cable and phone jack plugged into anauxiliary (aux) input in the front face of the entertainment system, or,alternatively, plugged into a pig-tail connector located in the vehicleglove compartment.

This arrangement enables the consumer to connect the vehicle audiosystem with their personal device. Some automobile radios have anauxiliary jack on the front of the radio. The auxiliary jack allowsplaying the music, but does not necessarily allow for player controlthrough the radio. This requires the device be accessible for control ofthe music.

The problems with the glove box approach are the potential for damage tothe device from other contents in the glove box, and the cableconnection offers no flexibility for connecting to another device.Damage may occur to the cable as well through normal use.

The auxiliary jack method allows more flexibility for devices, butlimits the control and may incur damage through impact while a plug isconnected.

Some aftermarket radios offer a USB (Universal Serial Buss) port on thefront panel thereof, but may also incur damage due to the potentialleverage on the face of the unit when a flash memory is connected, notto mention vehicle occupant impact issues resulting from braking andcollisions. Furthermore, connection interfaces open to the vehiclepassenger compartment environment risk system damage from foreignobjects and air-borne contamination, not to mention being aestheticallyunattractive.

With most automotive suppliers, the present generation of radios aretypically designed to fit a standard frontal area size. Typically, theDIN standard (issued by the Deutsches Institut für Normung, or GermanInstitute for Standardization) is used for either a “2DIN” or a single“DIN” size in most radios. 2DIN radios typically have larger displaysand contain multiple disc changers integrated into the package.

With the advent of music storage devices, like flash memory and deviceslike the iPod™, there is less dependency on multiple disc changers andmore desireability for the radio to communicate with the personal musicstorage or music device carried by the consumer. The rapidly changingcustomer market has initiated a drive to feature content on OEM(original equipment manufacturer) supplied radios for automobiles toprovide those wants and that has an impact on interchangability andpotential safety issues.

SUMMARY OF THE INVENTION

The present invention provides numerous product and process advantageswhich collectively result in substantial cost and labor savings. By wayof example, the preferred design optimizes the assembly process. Itminimizes the required handling of major components and subassembliesduring the assembly cycle. Final assembly is optimized, wherein onlyseven major components and subassemblies are involved. This minimizesthe number of work stations and fixtures, in-process transfers betweenwork stations and total assembly cycle time. The inventive designpermits selection of the optimal mechanical product configuration for agiven receiver family. Furthermore, it permits idealized electrical andmechanical building block partitioning for common and unique elements.

The preferred embodiment of the invention contemplates screwless finalassembly without the use of tools, fixtures and assembly machines. Thisgreatly enhances in-process product flow in the factory, improvesscheduling of final assembly, and allows labor intensive processes suchas stick lead assembly to be largely moved off-line. This greatlyreduces both direct and indirect labor requirements. Furthermore,inventory control is simplified inasmuch as position part proliferationis deferred to or near the end of process.

These and other features and advantages of this invention will becomeapparent upon reading the following specification, which, along with thedrawings, describes preferred and alternative embodiments of theinvention in detail.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described, by way of example, withreference to the accompanying drawings, in which:

FIG. 1, is an exploded, perspective view of a prior art automotiveradio/CD player combination in a common chassis constructed of sheetmetal and a large number of threaded fasteners;

FIG. 2, is a front-left perspective view of the preferred embodiment ofthe present invention embodied in an automotive radio/CD player;

FIG. 3, is an exploded, perspective view of the radio/CD player of FIG.2, illustrating the major subcomponents and subassemblies thereof;

FIG. 4, is an exploded, perspective view of the radio/CD player of FIG.2, illustrating final assembly step I in the production thereof whereinthe playback mechanism and circuit board assembly are slid and snappedto the faceplate;

FIG. 5, is an exploded, perspective view of the radio/CD player of FIG.2, illustrating final assembly step II in the production thereof whereinthe case is slid and snapped to the faceplate;

FIG. 6, is an exploded, perspective view of the radio/CD player of FIG.2, illustrating final assembly step III in the production thereofwherein the power device retainer clip and heat sink are consecutivelyanchored, pivoted and snapped to the side of the case;

FIG. 7, is an exploded, perspective view of the radio/CD player of FIG.2, illustrating final assembly step IV in the production thereof whereinthe trim plate assembly is snapped to the faceplate/back-end assembly;

FIG. 8, is a bottom plan view of the radio/CD player of FIG. 2;

FIG. 9, is a top plan view of the radio/CD player of FIG. 2;

FIG. 10, is a rear plan view of the radio/CD player of FIG. 2;

FIG. 11, is a fragmentary, perspective view of a portion of the rearsurface of the prior art radio/CD player of FIG. 1, illustrating themounting bushing assembly;

FIG. 12, is an exploded, cross-sectional view of the prior art mountingbushing assembly of FIG. 11;

FIG. 13, is a fragmentary, rear plan view of a rear integral mountingstud on an enlarged scale with a mating opening of a host vehicle rearmounting bracket superimposed thereon in phantom;

FIG. 14, is a fragmentary, cross-sectional view taken on lines 14-14 ofFIG. 13 with the mounting stud juxtaposed with pre mounting relationshipwith the host vehicle mounting bracket;

FIG. 15, is a perspective view of the circuit board assembly with groundclips installed thereon;

FIG. 16, is a fragmentary, cross-sectional view of a ground clip and anassociated portion of the printed circuit board on an enlarged scale inassembly with an adjacent portion of the case to effect a groundingpoint with the integral wire mesh;

FIG. 17, is a fragmentary, perspective view of a keypad grounding clipintegrally formed on the front side of the faceplate;

FIG. 18, is a cross-sectional view taken on lines 18-18 of FIG. 17;

FIG. 19, is a cross-sectional view taken on lines 19-19 of FIG. 17;

FIG. 20, is a cross-sectional view taken on lines 20-20 of FIG. 17;

FIG. 21, is a front perspective view of a prior art faceplateillustrating rivet/staked spring clips for ESD protection to associatedcontact pads on a trim plate assembly;

FIG. 22, is a perspective view of the outer side (as assembled) of anelectrical power device retainer/backing clip;

FIG. 23, is a perspective view of the inner side (as assembled) of theelectrical power device retainer/backing clip of FIG. 22;

FIG. 24, is rear-left perspective view of the initial placement of theretainer/backing clip of FIGS. 22 and 23 through a thermal port in theleft side wall of the case of the radio/CD player of FIG. 2;

FIG. 25, is a front-right perspective view of the initial placement ofthe retainer/backing clip through the thermal port corresponding to thedepiction of FIG. 24;

FIG. 26, is a rear-left perspective view of the final positioning of theretainer/backing clip in assembly with the left side wall of the case ofthe radio/CD player to effect rear surface support of the threeassociated electrical power devices;

FIG. 27, is a front-right perspective view of the final positioning ofthe retainer/backing clip in assembly with the case of the radio/CDplayer corresponding to the depiction of FIG. 26;

FIG. 28, is a rear-left perspective view of the initial placement of aheat sink adjacent the left side wall of the case of the radio/CD playerof FIG. 2;

FIG. 29, is a rear-left perspective view of the final positioning of theheat sink in assembly with the retainer/backing clip and the left sidewall of the case of the radio/CD player;

FIG. 30, is a fragmentary, cross-sectional view of the initialpositioning of a CD mechanism bracket with respect to a support shelfintegrally formed within the case;

FIG. 31, is a fragmentary, cross-sectional view of the CD mechanism inan intermediate position with respect to the support shelf during itsinstallation;

FIG. 32, is a fragmentary, cross-sectional view of the CD mechanism inits final installed position with respect to its associated supportshelf;

FIG. 33, is a fragmentary detail, on an enlarged scale, of the rear endportion retention tab of the CD mechanism bracket depicted in FIGS.30-32;

FIG. 34, is a cross-sectional view of a first portion of the retentiontab of the CD mechanism bracket taken on lines 34-34 of FIG. 33illustrating an integral dimply/crush rib formed therein;

FIG. 35, is a cross-sectional view of another portion of the retentiontab of the CD mechanism bracket taken on lines 35-35 of FIG. 33;

FIG. 36, is an end plan view of the retention tab of the CD mechanismbracket in its assembled position within the rear wall portion of thecase of the radio/CD player as depicted in FIG. 32;

FIG. 37, is a cross-sectional view of an alternative, lighter weightouter case configuration in representative assembly with a bifurcated PCboard wherein wire screen mesh provides both electromagnetic shieldingas well as a significant portion of the overall structural strength ofthe case;

FIG. 38, is a cross-sectional view of an alternative, guillotine or dropin place type aluminum plate heat sink in representative assembly withPC board mounted power ICs within a radio housing assembly;

FIG. 39, is a cross-sectional top view taken along lines 39-39 of FIG.38;

FIG. 40, is a broken, cross-sectional side view taken along lines 40-40of FIG. 38;

FIG. 41, is a broken, side plan view of an alternative design screwlessresilient power clip carried on a PC board adjacent a power device forbiasing the power device towards an opposed heat sink;

FIG. 42, is a broken, side plan view of the screwless power clip of FIG.41 with the heat sink in its installed position within a housing, andwith the clip continuously biasing the power device against an embossedinner surface of the heat sink;

FIG. 43, is a broken, side plan view of an alternative designfunctionally similar to that of FIGS. 41 and 42, but where the powerdevice lead frame is partially or completely formed of resilient springmaterial to replace the power clip;

FIG. 44, is a broken, cross-sectional view of a prior art rear loadedpushbutton employing flexible molded linkage in assembly with aswitch/contact pad, a printed circuit backer board and a front trimplate;

FIG. 45, is a broken, top cross-sectional view of the prior artpushbutton of FIG. 44 with the pushbutton in both a relaxed (solid line)position and an axially offset (in phantom) position;

FIG. 46, is a cross-sectional view of the prior art rear loadedpushbutton of FIG. 44 with the molded linkage in the relaxed position;

FIG. 47, is a cross-sectional view of the prior art rear loadedpushbutton of FIG. 44 with the molded linkage in the flexed position;

FIG. 48, is a cross-sectional view of an inventive 4-bar molded linkagefor a rear loaded pushbutton assembly with the linkage in a relaxedposition;

FIG. 49, is a cross-sectional view of the 4-bar molded linkage for arear loaded pushbutton assembly of FIG. 48 with the linkage in a flexedposition;

FIG. 50, is an exploded, perspective view of an array of integrallyformed 4-bar linkage for rear loaded push button assemblies of FIGS. 48and 49 juxtaposed with a decorative trim plate;

FIG. 51, is a process flow chart for molding, painting trimming,singulating and installing a button set in a host end-application devicewhile continuously maintaining the individual buttons of the set intheir end-application juxtaposition;

FIG. 52, is a plan view of an operator control panel of anend-application device with the buttons installed in their finalorientation;

FIG. 53, is a perspective view of a subset of three buttons in their asmolded state prior to installation in a paint fixture;

FIG. 54, is a perspective view of two three-button subsets installed ina paint fixture;

FIG. 55, is a process flow chart for prior art end of line detection ofIC faults performed by dedicated production line test equipment;

FIG. 56, is a process flow chart for end of line detection of faultcodes from ICs on the PCB in response to a microprocessor embedded testcode;

FIG. 57, is a process flow chart for a prior art system for updatingtime of day employing radio resonator offset;

FIG. 58, is a process flow chart for setting and periodically updatingthe time of day by programming the radio to tune to WWV on 100 KHz as aknown standard;

FIG. 59, is an exploded, perspective view of an alternative embodimentof a radio/CD player featuring an adjustable shelving feature forpositioning a CD player and one or more PC boards;

FIG. 60, is a front plan view of one of two shelf guide inserts employedin the radio/CD player embodiment of FIG. 59;

FIG. 61, is a top plan view of the shelf guide insert of FIG. 60;

FIG. 62, is a front plan view of the shelf guide insert of FIG. 60;

FIG. 63, is a cross-sectional view of the shelf guide insert taken onbroken lines 63-63 of FIG. 60;

FIG. 64, is a cross-sectional view of the shelf guide insert taken onlines 64-64 of FIG. 60;

FIG. 65, is a front plan view of a heat sink employed in the radio/CDplayer embodiment of FIG. 59;

FIG. 66, is a broken, cross-sectional view of initial positioning of theheat sink of FIG. 65 with respect to one of the shelf guide inserts ofFIG. 60 as part of the assembly process of the embodiment of theradio/CD player of FIG. 59;

FIG. 67, is a broken, cross-sectional view similar to that of FIG. 66,but with the heat sink in an intermediate position in the assemblyprocess;

FIG. 68, is a broken, cross-sectional view similar to that of FIG. 66,but with the heat sink in a fully installed position in the assemblyprocess wherein it is self-engaged and retained by an integralengagement tab of the shelf guide inserts;

FIG. 69, is a broken, cross-sectional view on an enlarged scale of avariant of the radio/CD player of FIG. 59 wherein the interconnectingfeatures between the shelf guide inserts and the CD player retentionshelf are complimentary dove-tails;

FIG. 70, is an exploded, perspective view of a second alternativeembodiment of a radio/CD player featuring an unfolded case whichprovides a single plane bottom up assembly configuration;

FIG. 71, is a representative cross-section of the case wall structure ofthe radio/CD player of FIG. 70, on a greatly enlarged scale,illustrating a thin wall section forming a living hinge;

FIG. 72, is a fragmentary, cross-sectional detail of adjacent case paneledge portions of the radio/CD player of FIG. 70, on an enlarged scale,in a post assembly orientation prior to engagement of cooperatingintegral latch features;

FIG. 73, is a fragmentary, cross-sectional detail of adjacent case paneledge portions of the radio/CD player of FIG. 70, similar to that of FIG.72, in a post assembly orientation after engagement of cooperatingintegral latch features;

FIG. 74, is a representative cross-sectional detail of a variant of thecase wall structure of the radio/CD player of FIG. 70, on a greatlyenlarged scale, illustrating a screen only section forming a livinghinge;

FIG. 75, is a schematic representation of manufacturing processequipment for producing a continuous strip of composite/laminate(plastic-screen-plastic) material for subsequent formation of the casestructure of the radio/CD player of FIG. 70;

FIG. 76, is a representative view, on a greatly enlarged scale, oflaminate case material produced by the process equipment of FIG. 75,illustrating a localized deformation of the material to define a reducedthickness, undulating living hinge section;

FIG. 77, is a schematic representation of alternative manufacturingprocess equipment for producing a continuous strip of composite (plastic& screen) material for subsequent formation of a case structure suitablefor the radio/CD player of FIG. 70;

FIG. 78, is an exploded, perspective view of a third alternativeembodiment of a radio/CD player featuring an I-beam structure allowingboth the control electronics PCB and the CD player to be assembled in abottom-up sequence;

FIG. 79, is a cross-sectional view of the third embodiment of a radio/CDplayer of FIG. 78, on an enlarged scale, with the control electronicsPCB and CD player illustrated in phantom;

FIG. 80, is an exploded, perspective view of a fourth alternativeembodiment of a radio/CD player featuring “clamshell” or “interlockingblock” upper and lower self-engaging case halves;

FIG. 81, is a broken, cross-sectional view, on an enlarged scale, ofinternal features of the case assemble of the radio/CD player of FIG.80, illustrating the self-engagement feature of the case halves and themounting/positioning of the PCB and CD player (illustrated in phantom);

FIG. 82, is a cross-sectional view, on an enlarged scale, of additionalinternal features of the case assembly of the radio/CD player of FIG.80, taken along lines 82-82 of FIG. 81, illustrating application of aguillotine heat sink and integral leaf springs for securing the CDplayer (not illustrated);

FIG. 83, is an exploded, perspective view of a fifth alternativeembodiment of a radio/CD player featuring an “H” shaped case wherein CDplayer mounting brackets comprise sidewalls of the case whichself-engage with top and bottom panels to effect closure of the case;

FIG. 84, is a simplified cross-sectional view of the radio/CD playerassembly of FIG. 83 illustrating the mounting of the PCB and the CDplayer within the case;

FIG. 85, is an exploded, perspective view of the preferred embodiment ofthe invention of FIGS. 2-10 from a right bottom perspective with thetrim plate assembly removed, as illustrated in FIG. 7, illustrating thelaser ablating of both machine and human readable unit specific and unitgeneric product information directly on an outer surface of the case ator near the end of the production line;

FIG. 86, is a process flow chart illustrating the laser ablating productinformation on the case as part of a sequence following finalprogramming and calibration and operation functionality testing;

FIG. 87, is a process flow chart illustrating the basic algorithm for aradio received time update process;

FIG. 88, is a process flow chart illustrating the first level of a twolevel time update process of FIG. 87, wherein the update of the freerunning timer simply rounds the current time value to the nearestminute;

FIG. 89, is a process flow chart illustrating the second level of a twolevel time update process of FIG. 87, wherein the clock is set basedupon BCD encode time information in the WWV signal;

FIG. 90, is a rear perspective view of a prior art automotive radio/CDplayer combination substantially similar to the device depicted in FIG.1;

FIG. 91, is a rear perspective view of the case/back-end for a radio/CDplayer embodying the present invention substantially similar to the casedepicted in FIGS. 2, 3 and 5-10, illustrating molded, one piece polymerconstruction;

FIG. 92, is a front perspective view of the preferred embodiment of theinvention, substantially similar to that of FIG. 2, but with I/0 controldevice function graphical detail highlighted;

FIG. 93, is a front perspective view of the interior surface details ofthe case/back-end of FIG. 91 illustrating the wire mesh screen which hasbeen insert molded within the case adjacent the inner surface portionsthereof;

FIG. 94, is a front-above perspective view of a partially assembledradio/CD player, substantially similar to that illustrated in FIG. 7(prior to installation of the trim plate assembly), illustrating, interalia, (1) three outwardly directed spring contacts carried by resilientmembers integrally formed with the faceplate and (2) the juxtapositionof the wire mesh within the faceplate adjacent the outer surfacethereof;

FIG. 95, is a front-left perspective view of the partially assembledradio/CD player of FIG. 94, illustrating the same features from adifferent perspective;

FIG. 96, is a fragmentary, perspective view of a keyboard assemblyprinted circuit board carried on the inside surface of the trim plateassembly illustrating one of three contact pads which, after assembly,register with and establish electrical interconnection with springcontacts illustrated in FIGS. 94 and 95;

FIG. 97, is an exploded, perspective view of a sixth alternativeembodiment of a radio/CD player featuring a modified I-beam caseconstruction wherein the case comprises an assembly of plastic/screencomposite and metal panels;

FIG. 98, is a front-side perspective view of a stamped metallicsub-assembly of the radio/CD player of FIG. 97 defining a front panel,partial sidewalls and CD player shelf;

FIG. 99, is a rear-side perspective view of the stamped metallicsub-assembly of FIG. 98;

FIG. 100, is a front plan view of the stamped metallic sub-assembly ofFIG. 98;

FIG. 101, is a top plan view of the stamped, metallic sub-assembly ofFIG. 98;

FIG. 102, is a right side plan view of the stamped, metallicsub-assembly of FIG. 98;

FIG. 103, is an inverted, rear side perspective view of the stamped,metallic sub-assembly of FIG. 98;

FIG. 104, is a rear plan view of the stamped, metallic sub-assembly ofFIG. 98;

FIG. 105, is a partially exploded, front-side perspective view of avariant of the sixth alternative embodiment of the radio/CD player ofFIGS. 97-104, wherein a (single) PCB and heat sink subassembly have beenpre-assembled in a bottom/partial sidewall molded plastic case componentand upper and lower case ventilation hole arrays have been deleted;

FIG. 106, is an exploded, rear-side perspective view of the radio/CDplayer of FIG. 105;

FIG. 107, is a front-right perspective view of the radio/CD player ofFIG. 105, as fully assembled;

FIG. 108, is a front-left perspective view of the radio/CD player ofFIG. 105, as fully assembled;

FIG. 109, is a rear-left perspective view of the radio/CD player of FIG.105, as fully assembled;

FIG. 110, is a rear-right perspective view of the radio/CD player ofFIG. 105, as fully assembled;

FIG. 111, is a fully exploded view of the radio/CD player of FIG. 105;

FIG. 112, is a front-right perspective view of the radio/CD player ofFIG. 97;

FIG. 113, is a rear-left perspective view of the radio/CD player of FIG.97;

FIG. 114, is an exploded, perspective view of the radio/CD player ofFIG. 97, from a rear-left perspective;

FIG. 115, is an exploded, front-right perspective view of a seventhalternative embodiment of the radio/CD player, featuring a modified“clamshell” or “interlocking block” type composite plastic caseconstruction;

FIG. 116, is an exploded, rear-left perspective view of the radio/CDplayer of FIG. 115;

FIG. 117, is an exploded, front-right perspective view of the radio/CDplayer of FIG. 115, wherein the PCB and heat sink have beenpre-assembled with a molded plastic case bottom panel and the CD playerhas been pre-assembled with a stamped, metallic sub-assembly similar tothat described in FIGS. 98-104 and the trim plate has been added;

FIG. 118, is an exploded, rear-left perspective view of the radio/CDplayer of FIG. 117;

FIG. 119, is an inverted, front-right perspective view of the radio/CDplayer of FIGS. 97-114, as fully assembled;

FIG. 120, is a perspective view of the back side of the trim plateassembly of the prior art radio/CD player illustrated in FIG. 1,illustrating the surface details thereof;

FIG. 121, is a perspective view from the outside of a front plate of aradio/CD player similar to that described hereinabove, illustratingthree light pipes integrally molded within the front plate, including aplurality of outwardly directed integral extensions which, inapplication, register with devices of an associated trim plate assembly(not illustrated);

FIG. 122, is a perspective view of the inside surface details of thefront plate of FIG. 121;

FIG. 123, is a front plan view of the outside of the front plate of FIG.121;

FIG. 124, is a perspective view of the outside surface of the frontplate of FIG. 121, with the three light pipes removed;

FIG. 125, is a perspective view of the outside surface details of thethree light pipes as removed from the front plate, but retaining theiroriginal juxtaposition;

FIG. 126, is a perspective view of the inside surface details of thethree light pipes as removed from the front plate, but retaining theiroriginal juxtaposition;

FIG. 127, is a broken, perspective view of the cockpit area of anautomobile, illustrating an instrument panel mounted prior artentertainment system interconnected with a personal music device (insolid line) through a front panel auxiliary input, and an alternativepersonal music device (in phantom) through a glove box configured pigtail;

FIG. 128, is a front-right perspective view of an alternative embodimentof a radio/CD player embodying another aspect of the present invention,including an (open) media drawer configured in the front trim plateassembly with a personal music device stored within the drawer andoperatively interconnected with the host radio/CD player system via acoupling cable;

FIG. 129, is a side cross-sectional view of the radio/CD player of FIG.128, with the drawer open and the personal music device beinginstalled/removed;

FIG. 130, is a side cross-sectional view of the radio/CD player of FIG.128, with the drawer fully closed and the personal music deviceinstalled inside;

FIG. 131, is a side, cross-sectional view of a drawer assembly similarto that of FIGS. 128-130, but with the addition of an interfaceelectronics package in the front portion of the media drawer tofacilitate electrical interconnection with the radio/CD player assembly;

FIG. 132, is a rear plan view of a media platform for replacing thedrawer of the radio/CD player of FIG. 128, the media platform includingan opening/closing guide system and media hold-down features;

FIG. 133, is a broken, bottom-rear perspective view of an audio systemassembly embodying an alternative embodiment of the present inventionillustrating internal PCB front and rear edge self-grounding withintegral features of the audio system housing assembly;

FIG. 134, is a broken, cross-sectional view, on an enlarged scale, ofthe rear edge of the PCB of FIG. 133 self-engaging and self-groundingwith exposed electrically conductive shield and guide tangs integrallyformed with the audio system housing assembly;

FIG. 135, is a broken, cross-sectional view, on an enlarged scale, ofthe front edge of the PCB of FIG. 133 self-engaging and self groundingwith exposed electrically conductive shield and guide tangs integrallyformed with the audio system housing assembly;

FIG. 136, is a broken, rear facing perspective view of the exposedelectrically conductive shield and guide tangs of FIG. 134, with the PCBremoved;

FIG. 137, is a broken, forward facing perspective view of the exposedelectrically conductive shield and guide tangs of FIG. 135, with the PCBremoved;

FIG. 138, is a broken, perspective, cross-sectional view of analternative approach to self-grounding a PCB, wherein a rearwardlydirected extension of the PCB containing grounding pads on the top orbottom (or both) surfaces thereof registers with an opening formed inthe rear wall of the case exposing electrically conductive screen;

FIG. 139, is a broken, cross-sectional view of the alternativeembodiment of FIG. 138, with the PCB is in its installed design positionwherein the extension has pierced the exposed screen and establishedelectrical connection between the grounding pads and the screen;

FIG. 140, is a bottom-rear perspective view of a CD player subassemblyaffixed to opposed left and right mounting brackets via integralsquirts;

FIG. 141, is a broken, cross-sectional view, on an enlarged scale, ofone of the squirts taken on line 139-139 of FIG. 140, as it is manuallyapplied (as illustrated in phantom) within an adjacent opening in the CDplayer subassembly;

FIG. 142, is a broken, perspective view, on an enlarged scale, of one ofthe squirts of FIG. 140;

FIG. 143, is a top plan view of an alternative embodiment of one of thesquirts of FIG. 140;

FIG. 144, is a perspective view of the front surface of the audio systemhousing assembly closure member illustrating integral locating andretention features for a trim plate assembly PCB;

FIG. 145, is a perspective view of the front surface of the audio systemhousing assembly closure member of FIG. 144, with the trim plateassembly PCB installed;

FIG. 146, is a rear-left, broken perspective view of an alternativeembodiment of a lightweight audio system featuring a screwless, plug-inmodule for enabling the radio portion of the system to be (re)configuredto accommodate any known satellite radio provider or hardware upgrade;

FIG. 147, is a perspective view of the audio system of FIG. 146 with theplug-in module (illustrated partially in phantom) in the fully installedposition;

FIG. 148, is a broken, cross-sectional view of the audio system of FIG.147, illustrating the electrical and mechanical interface of the modulewith the host audio system case;

FIG. 149, is a broken, cross-sectional view of a portion of FIG. 148, onan enlarged scale, illustrating the structural details of the screwlessmodule retention features;

FIG. 150, is a rear-right perspective view of a composite case of analternative design automotive audio system which has wall panels formednearly exclusively of electrically conductive screen supported along therespective edges thereof by a framework of a molded polymer basedmaterial;

FIG. 151, is a cross-sectional view taken on lines 151-151 of FIG. 31,illustrating the juxtaposition of an associated pair of guideways formedby a housing case and guide members formed by a CD changer mountingbracket with the bracket partially installed within the case;

FIG. 152, is a cross-sectional view taken on lines 152-152 of FIG. 32,illustrating the juxtaposition of the associated pair of guideways andguide members with the bracket fully installed within the case;

FIG. 153, is a cross-sectional view of an alternative configuration ofthe guideways/guide members of FIGS. 151 and 152, with the respectivecontacting surfaces angularly converging;

FIG. 154, is a cross-sectional view of a second alternativeconfiguration of the guideways/guide members of FIGS. 151 and 152, withthe respective contacting surfaces diverging and an electrical groundingconnection established therebetween;

FIG. 155, is a broken, plan view of the rear case wall screened openingof FIG. 138, on an enlarged scale, with the exposed screen having apattern of perforations formed therein;

FIG. 156, is a broken perspective view of the exposed screen of FIG.155, prior to formation of the perforations, and its juxtaposition withan aligned pair of punch-type forming dies;

FIG. 157, is a cross-sectional view, on an enlarged scale, similar toFIG. 138, wherein the PCB extension carries a screen piercing tool whichis integrally formed with the upper and lower grounding pads;

FIG. 158, is a broken, top view of the integrated grounding pad/piercingtool as carried on a PCB extension;

FIG. 159, is a cross-sectional schematic view of a simplified inventivethermal control apparatus similar in many respects to the embodiment ofthe invention depicted in FIGS. 22-29;

FIG. 160, is a fragmentary, cross-sectional view of the initialpositioning of a CD mechanism bracket with respect to an alternativesupport shelf integrally formed within the case, similar to FIG. 30,with the wall surfaces defining the guideways each tapered on theirupper and lower surfaces to provide a drafted condition to enhanceinjection molding formation of the case;

FIG. 161, is a perspective view of an assembled telematics device forautomotive two-way communication/receiver systems;

FIG. 162, is a perspective view of the telematics device of FIG. 161,with the case open to illustrate its one-piece, living-hingeconstruction;

FIG. 163, is an exploded, perspective view of the telematics device ofFIGS. 161 and 162, illustrating the details of internal subassemblies;

FIG. 164, is a broken, cross-sectional view of a portion of the audiosystem housing case wherein the electrical interface plug includes aconnector body which is integrally formed with the housing case;

FIG. 165, is a broken, cross-sectional view of the audio system caseclosure member/trim panel formed of two-shot molded polymeric materialshaving different opacities;

FIG. 166A, is a broken, cross-sectional view of a portion of the audiosystem case and media drawer illustrating a “push-push” latch andopening spring with the media drawer in the closed and latched position;

FIG. 166B, is a broken, cross-sectional view of a portion of the audiosystem case and media drawer similar to FIG. 166A, with the media drawerin a partially opened and released position;

FIG. 167, is an exploded side plan view of a closure member (frontplate), switch/display printed circuit board (PCB), trim plate assemblyand decorative facia for an automotive radio/CD player;

FIG. 168, is a broken, cross-sectional view of the facia of FIG. 167, onan enlarged scale, with first surface finishing;

FIG. 169, is a broken, cross-sectional view of an alternative facia,similar to that of FIG. 168, with second surface finishing; and

FIG. 170, is a broken, cross-sectional view of a front loaded, colorshifting actuator button in assembly with a rear loaded actuator device(ex. switch) and extending through a registering opening in anassociated trim plate/panel.

Although the drawings represent varied embodiments and features of thepresent invention, the drawings are not necessarily to scale and certainfeatures may be exaggerated in order to illustrate and explain thepresent invention. The exemplification set forth herein illustratesseveral aspects of the invention, in one form, and such exemplificationis not to be construed as limiting the scope of the invention in anymanner.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

The present invention can be applied in its broadest sense to electronicdevices and systems where shielding from radio frequency interference(RFI), electromagnetic interference (EMI), bulk current injection (BCI)and/or electrostatic discharge (ESD) is required. In addition to vehiclebased radios and audio entertainment systems, the invention can beadvantageously applied in “infotainment” and telematic systems.Furthermore, the present invention employs virtually “fastenerless”design architecture to facilitate low-cost, high volume productiontechniques.

A telematics product is a two-way communication/receiver system thatenables access by a vehicle occupant to vehicle related information likegeographic position/location through the use of a GPS module withantenna, vehicle diagnostics, crash sensors and air bag deployment. Italso contains a phone module that is linked through a microphone in thevehicle and the radio speaker system for hands free calling via voicerecognition and links to a call center for a variety of services,including but not limited to emergency help, concierge, vehicle theftrecovery, turn-by-turn route guidance, vehicle diagnostics and vehicleunlock.

For convenience of understanding, the following description will befocused primarily upon an automotive radio/CD player system.

Lightweight Radio/CD Player For Vehicular Application (1)

The present invention reflects an improved design to reduce the overallweight of an automotive radio/CD player without compromising thestrength of the unit. The present invention employs a polymer basedmaterial that can be molded to provide the necessary features for thechassis as well as the frontal interface to the decorative front-endassembly described for the man-machine interface. By molding a case withthe necessary details to accept the playback mechanisms (if desired) aswell as the circuit board(s) needed for the electrical control, therequired functionality of the unit is maintained as compared to thetypical metal box. The necessary shielding and grounding is accomplishedby insert-molding a mesh screen wire that has been pre-formed to contourwith the molding operation. The grounding of the circuit boards may beaccomplished by using ground clips attached directly to the ground padsof the circuit board that would interface directly with exposed screenwire mesh of the molded part. While metal is also a good conductor forthe thermal load inside the unit, openings must be incorporated to allowairflow for additional cooling. The same openings can compromise theshielding. With in-molded mesh screen wire, the mesh acts as a Faradaycage to shield the electronics, but the open weave allows airflow topromote the dissipation of the thermal load from inside the unit, to theexterior. Besides the reduction of mass offered by the molded polymermaterial for the unit chassis and front plate, the hidden benefitsinclude ease of handling in the assembly process as well as lesscontainer and shipping weight.

To facilitate assembly, the molded polymer chassis and front plate canuse integral or molded in guideways and snaps, thereby eliminating thetypical screw fastener assembly method previously used for thesecomponents. To enhance the rigidity, the component parts that comprisethe assembly are sandwiched at the common vehicle instrument panelattachment points such that when the mounting screws are driven, theyfirmly clamp the component pieces to the host vehicle. In the event aplayback mechanism of substantial mass and volume is required, thesub-assembly structure for the mechanism would utilize formed attachmenttabs that would be an intermediate layer in the aforementioned componentpart sandwich. Another benefit for the mounting at the back of the radiois often vehicles have a receptive hole or slot in the inner cavity ofthe instrument panel carrier that accepts a mounting bushing or “bullet”shaped extension that is screwed to a mounting stud that is typicallyswaged to the back of the metal enclosure of the radio. The mounting“bullet” can be molded directly in the polymer-based case eliminatingthe additional part and the assembly of that additional part.

To replace the metal structure of the vehicle radio, a galvanized (orappropriately coated) steel mesh wire screen will be cut, formed, andmolded with a polymer resin to provide necessary details for assembly ofcomponents required for the functionality of the radio including, butnot limited to, a circuit board assembly, a heat sink for audio powerand switching components, a playback mechanism, and a man-machineinterface or trim plate assembly, as well as vehicle mounting features.While the polymer or plastic provides the majority of the mechanicalstructure for the radio, the in-molded mesh screen wire provides theneeded protection from various electrical anomalies includingelectromagnetic contamination, radio frequency interference, bulkcurrent injection, and electrostatic discharge, to name a few. Thescreen mesh also allows openings necessary for air passage or venting ofheat from the radio by molding the radio back end or case and frontplate. The many details and features needed in a typical assembly can beincorporated directly into the parts, eliminating the need for fastenersand separate additional parts often required with parts fabricated inmetal.

The specific materials selected for fabricating the radio case and frontplate will vary depending upon the application, including the containedmass of the mechanisms employed as well as the severity of thecontemplated environment (esp. temperature and vibration). Examples ofmaterials that could be employed for typical automotive applicationsare:

Case: Glass-filled polyester, Glass-filled polypropylene, Polycarbonate,ABS.

Front Plate: Polycarbonate, ABS, PC/ABS and Noryl.

Major components which contact one another or are mechanicallyinterconnected preferably are formed from material having substantiallydiffering surface finish and hardness characteristics to minimize thepossibility of resulting squeaks, rattles and the like.

Although presently viewed as cost prohibitive for automotiveapplications, it is contemplated that nano carbon tube filler can beemployed within the plastic material forming the case and front plate toprovide effective shielding and enhance the structural strength of thecase assembly.

In addition to weight savings, which may amount to well over one pound(0.4536 Kg), the part handling is improved to reduce the amount offasteners as well as separate component parts. Often a radio may beconstructed from a wrap-around, a cover and the fasteners along with amounting bushing or “bullet” screwed to a “swaged” threaded stud in themetal case. Also, the metal pieces require assembly personnel to weargloves during handling to avoid any cuts or damage to their hands aswell as protection from any metal fabrication fluid residue. Moldedplastic does not require any special gloves, or the concerns of cuts tothe skin. Aside to the benefit to the vehicle by reducing the radioweight by over one pound (0.4536 Kg), the savings for a manufacturerinclude reduced shipping cost through the weight reduction and potentialcontainer efficiency improvements. Product labeling can be improvedthrough laser engraving the plastic with the desired number, customerlogos, etc. Metal typically requires a stamping detail (not easilychanged) and/or a printed label that is adhesively applied. This offersgreater flexibility and eliminates additional parts (like labels) to usethe plastic, as well as better durability than a label.

Referring to FIGS. 2-10, a consolidated radio/CD player apparatus 62embodying many aspects of the present invention is illustrated. Theradio/CD player 62 is an assemblage of six major components orsubassemblies, a circuit board subassembly 64, a CD player subassembly66, a box-like housing case 68, a front closure member or front plate70, a convector or heat sink 72 and a trim plate subassembly 74.

It is envisioned that each of the major components/subassemblies wouldbe produced “off-line” and the final assembly process would comprise theefficient, high volume joining of the major components/subassemblies andend-of-line testing of the completed units.

FIGS. 2 and 8-10 depict plan and perspective views of the fullyassembled radio/CD player apparatus 62. FIG. 3 is an exploded viewillustrating the juxtaposition of the respective major components duringthe assembly process. FIGS. 4-7 depict specific assembly steps of themajor components as will be described hereinbelow.

The case 68 and front plate 70 are each preferably injection molded ofpolymer based material and collectively comprise a substantially closedhousing assembly 76. The case 68 has a box-like structure, includingupper and lower wall portions 78 and 80, respectively, left and rightside wall portions 82 and 84, respectively, and a rear wall portion 86.The case 68 also has mounting features extending externally of the casewalls, including left and right front mounting flanges 88 and 90,respectively, extending from the forward edges of the left and rightside walls 82 and 84, respectively, and a mounting stud 92 extendingrearwardly from the rear wall 86. All of the case wall portions andmounting features of the case 68 are integrally formed in a singleinjection molding process. The case defines a front opening 94 which,upon assembly, is closed by front plate 70. An assembly axis 96 extendssymmetrically from front to rear of the case 68, exiting opening 94along the nominal centerline of the case 96.

The circuit board subassembly 64 consists of a common or main printedcircuit board (PCB) 98 and a unique, application specific PCB 100 whichare electrically and mechanically interconnected by several pinconnectors 102. It is envisioned that edge connectors, ribbon connectorsor the like could be substituted for the pin connectors 102. The commonPCB 98 contains all surface mount components. The circuit boardsubassembly 64 comprises an audio component.

The CD player subassembly 66 consists of a conventional multi-discplayer unit 104 and substantially mirror-image left and right sidemounting brackets 106 and 108, respectively, affixed thereto by integralfastener devices such as “squirts” (refer FIGS. 141-143). Note thatthere are slight differences between the left and right mountingbrackets 106 and 108, but they are deemed to be inconsequential forpurposes of the present invention. The left and right mounting brackets106 and 108 have outwardly directed mounting flanges 110 and 112,respectively, which, upon assembly, register with case mounting flanges88 and 90, respectively. The CD player subassembly 66 comprises an audiocomponent.

The heat sink 72 comprises a substantially flat, stamped aluminum plateadapted for mounting to the outer surface of the left case sidewall 82and includes a recessed portion 114 which, upon installation, extendsinwardly through a port 116 in left case sidewall 82 for thermalinterconnection to heat generating and power circuit components 118, 120and 122 carried on the main PCB 98.

The trim plate subassembly 74 is configured to organize audio systeminput/output and display devices, informational indicia and decorativedisplay devices for an associated host vehicle operator.

Referring particularly to FIGS. 4-7, a method of assembly of thelightweight audio system 62 of the present invention is illustrated.Audio system 62 can be assembled manually by an ordered process whereina single (preferably, but not limited to) operator, who sequentiallyassembles the six major components or subassemblies on a designated worksurface 124. No specialized tools or separate/dedicated fixtures arerequired. No threaded fasteners/screws are required. Each or the majorcomponents and subassemblies form integral features which cooperate tointeract with features of the other components and subassemblies toregister, align and guide the components and subassemblies duringadjoining thereof as well as to removably affix the components andsubassemblies to one another when in their final design position. Thisprocess is referred to herein as the Slide-lock Snap-lock™ ScrewlessAssembly Technology and Method or “SLAT”. In effect, the components“self-fixture one another in combination the manipulation of the

Assembly of the radio/CD player 62 is affected by the assemblytechnician or operator taking the following steps:

As illustrated in FIG. 4, place the front plate 70 on the work surface124 in an inverted position with the outer surface of the front platedisposed upon the work surface 124. The centerline of the front plate 70defines an assembly axis, as designated by arrow 96 extending normallyto the work surface 124.

The front plate has two laterally spaced, rearwardly directed extensions126 and 128 integrally formed therewith. Extensions 126 and 128 formguideways or opposed slots 130 and 132, respectively, which open towardsone another and are directed parallel to the assembly axis 96. Lateraledge guide surfaces 134 and 136 of the application specific PCB 100register within slots 130 and 132 and are guided thereby during theinsertion process until the leading edge surface 138 of the PCB 100contacts the inside (upward facing in FIGS. 4 and 5) surface of frontplate 70. At this point, common PCB 98 is cantilever suspended from PCB100 via pin connectors 102 and other supports (not illustrated).Referring FIG. 5, the circuit board subassembly 64 is retained inposition by the interfit of the edge surfaces 134 and 136 within slots130 and 132.

The CD player subassembly 66 is next installed by manipulating it alongthe assembly axis 96 until through holes 140 and 142, formed in bracketmounting flanges 110 and 112, register with locating pins or nibs 144and 146 integrally formed in laterally extending mounting flanges 148and 150, respectively, integrally formed in front plate 70. Thereafter,the CD player subassembly is displaced downwardly along the assemblyaxis 96 until the lower surfaces of bracket mounting flanges 110 and 112abut the upper surfaces of front plate mounting flanges 148 and 150. TheCD player subassembly 66 is retained in the position illustrated in FIG.5 by an interference fit between the front plate nibs 144 and 146, andthe mounting bracket flange through holes 140 and 142.

Mounting bracket flanges 110 and 112 have secondary, larger diameterthrough holes 152 and 154 formed therein which register with similarlydimensioned through holes 156 and 158, respectively, formed in frontplate mounting flanges 148 and 150 for receiving attachment means suchas bolts, for affixing the completely assembled radio/CD player 62 to ahost vehicle.

The steps of installing the circuit board subassembly 64 and the CDplayer subassembly can be reversed from that describer hereinabove.

The housing case 68 is next installed by manipulating it along theassembly axis 96 whereby the case wall portions 78, 80, 82, 84 and 86fully envelop the circuit board subassembly 64 and CD player subassembly66 in combination with the front plate 70.

As best viewed in FIGS. 3, 5 and 93, the centerline of the case 68 isfirst manually aligned with the assembly axis 96 and rotationallypositioned with the subassembly consisting of the circuit boardsubassembly 64, CD player subassembly 66 and the front plate 70, wherebya first cooperating pair of guideways 160 and 162 integrally formed incase sidewall portions 82 and 84 register with the CD player mountingbrackets 106 and 108 and, simultaneously, a second cooperating pair ofguideways 164 and 166 integrally formed in case sidewall portions 82 and84 register with lateral edge guide surfaces 168 and 170 of common PCB98. The case 68 is then manually displaced along the assembly axis 96until the leading edge thereof defining front opening 94 contacts therear surface of the front plate 70. Thereafter, cooperating rampedsnap-engagement features 172 and 174 integrally formed with upper andlower wall portions 78 and 80 of the case 68 and the front plate 70,respectively, momentarily self-displace one another and snap back toself-engage to establish a positive interlock therebetween.

The case mounting flanges 88 and 90 form through holes 176 and 178 whichregister and self-engage with nibs 144 and 146, respectively, to providea redundant engagement feature. Furthermore, the case mounting flanges88 and 90 form a second set of through holes 180 and 182, respectively,which register with through holes 152 and 154 of mounting brackets 106and 108, and through holes 152 and 154 of front plate mounting flanges148 and 150, respectively.

As best viewed in FIGS. 2, 6 and 7, the heat sink 72 is next installed.The heat sink 72 includes several locating tabs 182 integrally formedalong one edge thereof and a locator recess 184 formed in an opposededge. The heat sink 72 is manually affixed to the outer surface of thecase left side wall portion 82 which defines integral tab receivingextensions 186 along the upper edge thereof. Once the heat sink locatingtabs 182 are inserted within their respective case wall portionextensions 186, the heat sink 72 is rotated into its design positionillustrated in FIG. 7 wherein a resilient ramped catch member 188integrally formed along the bottom edge of the left side wall portion 82snap engages the recess 184 to fixedly interlock the heat sink 72 to thecase 68.

When the heat sink 72 is in its installed position, the recessed portion114 extends inwardly into the case 68 through the port 116. The innersurface of the recessed portion 114 establishing an abuttingrelationship against the power circuit components 118, 120 and 122 toprovide a cooling thermal convector to the exterior of the case 68.Means are provided to ensure that components 118, 120 and 122 remain inintimate contact with the heat sink 72 such as screws 190, or,preferably (as illustrated in FIGS. 22-29 and 41-43) to continuouslyresiliently urge the components into engagement with the recessedportion 114 of the heat sink 72.

It is contemplated that the heat sink 72 could be alternatively mountedto the case rear wall portion 86, whereby it would be installed alongthe assembly axis 96.

Referring to FIG. 7, the final step of assembling the major componentsand subassemblies is illustrated. First, the subassembly of thecomponents illustrated in FIG. 6 is manually inverted, with the caserear wall portion 86 disposed on the designated work surface 124. Due tothe localized outward projection of the stud 92, a stability enhancingspacer (not illustrated) or, alternatively, a recess 192 in the worksurface 124 ensures a stable platform to complete assembly.

The trim plate subassembly 74 is then manipulated to become in registerwith the case 68 and manually displaced along the assembly axis 96 untilthe lower surface of the trim plate assembly 74 contacts the uppersurface of the front plate 70 (as depicted in FIG. 7). Thereafter,cooperating ramped snap-action engagement features 192 and 194integrally formed with upper and lower edge skirt surfaces of the casetrim plate assembly 74 and the front plate 70, respectively, momentarilyself-displace one another and snap back to self-engage to establish apositive interlock therebetween.

The completed assembly of the major components and subassemblies isdepicted in FIGS. 2, 8-10 and 92. Following the assembly process, thecompleted radio/CD player 62 is placed in a queue for testing andquality checks.

Molded-In Integrated Mounting Bushing (2)

The rear mounting bushing for current radios is typically attached bywelding a threaded stud to the back wall of the wrap around and then thebushing is screwed on. With the plastic box receiver, the mountingbushing can be molded as an integral part of the receiver box,eliminating two part numbers and the labor to install them.

Referring to FIGS. 11 and 12, a typical prior art stud 54 is illustratedas part of a conventional radio/CD player 10.

Referring to FIGS. 5-10, 13 and 14, a feature of the present inventionis illustrated wherein the stud 92 is integrally formed with the housingcase 68, such as through injection molding. The stud 92 functions tosupport the rear portion of the radio/CD player assembly 62 wheninstalled in the host vehicle. Upon installation of the radio/CD playerassembly, the rearwardly directed stud 92 registers with an opening 196in a vehicle structural support member 198.

The stud 92 is elongated and has a characteristic cross or “+” shapedcross-section along its axial length. The cross-section configuration ofthe stud 92 has intersecting vertical and horizontal portions 200 and202, respectively. The outwardmost surfaces of the vertical andhorizontal portions 200 and 202 are dimensioned to establish aninterference fit within the opening 196 of the support member 198.Because the stud 92 is constructed of softer material (plastic) than thesupport member 198 (steel), the outer surfaces of the vertical andhorizontal portions will tend to deform locally upon insertion intoopening 196 and thereby assure a tight, rattle free connection.Rearwardly directed edges 206 are configured with a sharp transitionwhich will scarf the plastic material of the stud 92 upon any withdrawalfrom the opening.

As is best illustrated in FIG. 93, vertical and horizontal bosses 208and 210, respectively, are located directly interiorly of the stud 92 toreinforce the rear wall portion 86 of the case 68 to prevent“oil-canning” and allows use of relatively thin wall section forenhanced weight saving.

FIGS. 93-95 illustrate an alternative construction of the case 68 andfront plate 70 of the housing assembly 76 wherein both elements of thecase assembly 76 are formed of a composite of relatively rigid polymermaterial and electrically conductive material operable to shield theaudio components (such as the circuit board subassembly 64 and the CDplayer subassembly 66) from electrical anomalies including radiofrequency interference (RFI), electromagnetic interference (EMI), bulkcurrent injection (BCI) and electrostatic discharge (ESD). Theelectrically conductive material comprises substantially continuousplaner sheet portions applied to surfaces of or within polymer housingassembly wall portions as discrete elements, electrically conductivepaint, foil or electrostatic or vacuum deposition applied material.Alternatively, the electrically conductive material comprises a wiremesh screen 212 which has been cut and folded to net shape and insertedwithin a mold cavity whereby it is effectively insert molded within thepolymer based material. Preferably, the wire screen 212 is centeredwithin the wall portions of the case and front plate wherebyelectrically insulating polymer material effectively covers the wirescreen 212, both inside and out, to prevent inadvertent grounding of thehousing assembly to interior or exterior structures.

Through empirical testing and development, the inventors have found thatit is preferable to locate the wire screen 212 near the inside surfaceof the case 68 and the outside surface of the front plate 70. Openings214 are provided in the case 68 by locally eliminating the polymermaterial but leaving the wire screen intact, whereby judiciouslypositioned openings 214 provide natural convection cooling to theambient without having a break or gap in the electrical anomalyprotection provided by the wire screen 212.

Circuit Board Grounding to Wire Mesh System (3)

The common circuit board and the unique circuit board are grounded tothe molded in wire mesh by using a grounding clip that contacts theground plane on the circuit board to the metal mesh by pressing thecircuit board with the clip installed into a hole or recess in theplastic box that exposes the mesh. A point/ridge/protuberance is used onthe clip to press into the mesh and increase the pressure for intimatecontact. An alternative of this clip is one that gets surface mountedand soldered to the board and does not require manual assembly.

Referring to FIGS. 15 and 16, one form of grounding the ground plane 216of the circuit board subassembly 64 to the wire screen 212 isillustrated. The leading edge surface 138 of the unique PCB 100 carriestwo beryllium copper grounding clips 218, which are electrically andmechanically connected to the PCB ground plane 216. Similarly, atrailing edge surface 222 of the common PCB 98 carries two groundingclips 218. Each grounding clip 218 includes a resilient contact arm 220extending outwardly along the assembly axis 96. Upon assembly, thegrounding clips 218 carried on the leading edge surface 138 of PCB 100register with exposed wire screen 212 within windows 224 in front plate70 (refer FIGS. 94 and 95), and the grounding clips 218 carried on thetrailing edge surface 222 of PCB 98 register with exposed wire screen212 within windows 226 in the rear wall portion 86 of the case 68. Thecontact are 220 of each grounding clip 218 is configured to continuouslybear against the adjacent exposed wire screen 212 to maintain electricalcontact therewith.

Referring to FIGS. 133-139 and 155-158, alternative forms of groundingthe ground plane 216 of the circuit board subassembly 64 to the wirescreen are illustrated. FIG. 133 illustrates a radio/CD player 622similar in all material respects to the radio/CD player 62 describedhereinabove in connection with FIGS. 2-10 and 15-20 inter alia, with theexceptions described immediately hereinbelow. In essence, in thisembodiment, the four ground clips 218 contained on the circuit boardsubassembly 64 are deleted and replaced by connectors integrally formedwith the housing assembly 76.

Referring to FIGS. 133, 135 and 137, a circuit board subassembly 624includes a common PCB 626 interconnected with a unique PCB 628 by pinconnectors 630. A leading edge 631 of the unique PCB 628, when installedwithin a front plate 632, engages two Z-clips 634 integrally formedwithin the front plate 632, whereby wire screen 636 exposed in theZ-clip 634 engages a contact pad/plane 638 carried on the unique PCB 628adjacent its leading edge 631. A trailing edge 652 of the common PCB626, when installed in a housing case 654, engages two grounding clips658 integrally formed within the case 654, whereby wire screen 636exposed in the grounding clip 656 engages a contact pad/plane 658carried on the common PCB 626 adjacent its trailing edge 652.

As best viewed in FIGS. 135 and 137, the Z-clip 634 includes a frame 640integrally formed adjacent one side of an associated opening 642 andextending inwardly (within an associated housing case 643) therefrom asa resilient cantilever. The frame 640 includes two parallel “L” or “J”shaped leg portions 644 interconnected by a cross support portion 646. Aflap of wire screen 636 is die-cut prior to being injection moldedwithin the front plate 632. During the injection molding process, theedges of the wire screen flap are insert molded within the leg portions644, the cross-support portion 646 and the adjacent front panel of thefront plate 632, thereby exposing the wire screen flap 636 forelectrical connection with the unique PCB contact pad 638. An inwardlydirected boss 648 is integrally formed on the front plate 632 adjacentan edge of the opening 642 opposite from the leg portions 644, andextends substantially parallel to an assembly axis 649. The boss 648forms a guide/abutment surface 650 which is spaced from the exposed wirescreen flap 636 by a dimension slightly less than the thickness of theunique PCB 628 to ensure a tight compressive fit when the leading edge631 of the unique PCB 628 is inserted therebetween. The naturalresiliency of the polymer material forming the Z-clip frame 640 ensurescontinued continuity of the electrical connection between the exposedwire screen 636 of the Z-clip and the unique PCB contact pad 638.

As best viewed in FIGS. 134 and 136, the grounding clip 656 includes acooperating pair of laterally spaced support members 660 and 662integrally formed in a rear wall portion 664 of the case 654 adjacentthe bottom edge of an associated opening 663 and extending inwardlytherefrom. A flap of wire screen 666 is die-cut prior to being injectionmolded within the case 654. During the injection molding process, thelateral edges of the wire screen flap 666 are insert molded within thesupport members 660 and 662 and the adjacent portion of the case rearwall portion 664, thereby exposing the wire screen flap 666 forelectrical connection to the common PCB 626 contact pad 658. A wirescreen positioning finger 668 is integrally formed in the rear wallportion 664 of the case 654 laterally intermediate the support members660 and 662, and extends inwardly from the rear wall portion 664substantially parallel to an insertion axis 670 as a resilientcantilever. The positioning finger 668 is vertically positioned withrespect to the support members 660 and 662 to continuously contact thelower surface of the wire screen flap 666 to ensure that the lateralcenter portion of the wire screen flap 666 is bowed slightly upwardlyand resiliently maintained at least slightly above the upper surfaceportions 672 and 674 of the support members 660 and 662, respectively.An inwardly directed boss 676 is integrally formed on the rear wallportion 664 of the case 654 adjacent the top edge of the opening 663opposite from and laterally centered with the support members 660 and662. The boss 676 forms a guide/abutment surface 678 which is spacedfrom the exposed wire screen flap 666 by a dimension slightly less thanthe thickness of the common PCB 636 to ensure a tight compressive fitthen the trailing edge 652 of the common PCB 636 is insertedtherebetween. The natural resiliency of the polymer material forming theground clip 656 structural elements ensures continued continuity of theelectrical connection between the exposed wire screen 666 of the groundclip 656 and the common PCB contact pad 658.

Referring to FIGS. 138 and 139, another example of self-grounding isillustrated wherein a PCB 680 includes an extension 682 projectingforwardly therefrom in line with an assembly axis 684 of a housing case686 for an audio system 687. Contact pads 688 and 690 are carried onupper and lower surfaces 692 and 694 of the PCB extension 682. A rearwall portion 696 of the case 686 forms a window 698 exposing a portionof wire screen 700 which is aligned with the PCB extension 682. When thewire screen 700 is insert molded within the polymeric material formingthe case 686, the portion thereof coinciding with the window 698 is leftintact. During the assembly process of the audio system 687, wherein thePCB is installed by insertion along guideways (not illustrated) withinthe case 686, the PCB is inserted with sufficient force to locallyrupture and penetrate the exposed wire screen 700 within the window 688.Following the rupture of the wire screen 700, the residual separationedges thereof are drawn into the window 698 by friction caused by motionof the upper and lower PCB surfaces 692 and 694, respectively. When thePCB 680 assumes its installed position, as illustrated in FIG. 139, therended portions of the wire screen 700 are compressively fit between thecontact pads 688 and 690 and the adjacent edges of the window 698,ensuring continued continuity of the electrical connection between theexposed wire screen 700 and the PCB contact pads 688 and 690. It iscontemplated that a single (one side of the PCB) contact pad can also beemployed. However, the redundancy afforded by the dual contact pads 688and 690 is preferable.

Referring to FIGS. 155 and 156, a modification of the self-groundingsystem described in connection with FIGS. 138 and 139 can enhanceassembly of an audio system 702 for simplified and improved unit-to-unitrepeatability. A housing case 704 includes a wall portion 706 forming awindow 708 exposing a wire screen 710 to establish a point of electricalconnection to an audio component within the case 704. After the wirescreen 710 is insert molded within the polymer material forming the case704, but before the assembly if the audio system 702, a tool, such as acooperating punch 712 and die 714 is pressed simultaneously against theinner and outer surfaces of the exposed screen 710 within the window 708to form perforations or weakenings, indicated by dotted lines 716. Thisprocess step is indicated by arrows 718. The perforations 716 make theexposed wire screen 710 more predictably frangible for improvedunit-to-unit quality. Thereafter, during final assembly of the audiosystem 702, the wire screen 710 separates along the perforations 716when contacted by the leading edge of a PCB extension 682 (refer FIGS.138 and 139).

Referring to FIGS. 157 and 158, an alternative self grounding approachinvolves modifying a leading surface 720 of an extension 722 of a PCB724 to form a sharpened, laterally extending leading edge 726. Theleading edge 726 can be formed by the PCB material itself or,preferably, by hardened material, such as a metal appliqué or bandformed in a “U” or a “V” configuration engaging the PCB 724 by upper andlower members 728 and 730 affixed to the upper and lower surfaces 732and 734 of the PCB extension 722 such as by soldering. The upper andlower members 730 and 732 can serve as electrical ground pads. Uponinstallation of the PCB 724, the sharp leading edge 726 first contactsand cleaves the exposed wire screen 710 into the form illustrated inFIG. 139.

In addition to the forgoing, punch dies 712/714 such as those depictedin FIG. 156 can be employed in modified form to actually sever and/orremove a portion (or all) of the wire screen 710 after the molding ofthe housing case 704, but before the final assembly of the audio system702. Furthermore, one or more service access windows can be providedelsewhere in the walls of the housing case 704. The service windows areclosed at the time of manufacture by exposed screen includingperforations, as depicted in FIG. 155. The exposed screen could besevered by a tool or process later in the service life of the audiosystem 702 to service or modify the system.

Front Plkate ESD Grounding to Keyboard Through Wire Mesh (4)

The method of grounding the plastic front plate (with molded in metalmesh) to the keyboard is by using plastic spring clip that contains anopen window to expose the mesh where the spring clip comes into contactwith a tinned pad on the keyboard. This provides an ESD path to groundwhen inserting a static charged CD into the CD changer.

Referring to FIGS. 17-21 and 94-96, several spring clip structures 228are integrally formed in the front plate 70 which, in assembly,continuously resiliently bear locally exposed segments of the wirescreen 212 against a tinned grounding pad 230 (only one is illustrated)on a keypad PCB 232 to establish a ground path therebetween.

Each spring clip structure 228 has a frame 234 including two parallelarc shaped portions 236 and 238 and a cross-support portion 240integrally formed with front plate 70 and extending therefrom as aresilient cantilever. An opening 242 in the front plate registers witheach spring clip 228 to permit flexure thereof.

Prior to molding of the wire screen 212 within the front plate 70 thescreen preform is die-cut to form an integral flap which is capturedwithin the mold and the edges thereof encased within arc-shaped portions236 and 238 and cross-support portion 240. The central portion of theexposed wire screen is expanded or stretched to form an outward bowshape (refer FIGS. 18 and 20) to ensure that the resulting exposedscreen protuberance firmly contacts the PCB grounding pad 230.

Referring to FIG. 21, a prior approach is illustrated wherein separatespring grounding clips 244 are each mechanically affixed to the frontplate 246 of a radio/CD player assembly 248 by a rivet 250 or othersuitable fastener. The rivets are required to establish an electricalground path as well as to mechanically secure the spring clips 244 tothe front plate 246, adding labor, cost and complexity to themanufacturing process.

Front Plate with Integal Assembly Fixturing (5)

Using a plastic front plate enables assembly fixturing for the CDmechanism and circuit boards for slide lock and snap lock assemblyinstead of the screws used in a traditional receiver.

Referring to FIGS. 4 and 5, guideways in the form of slotted extensions126 and 128, as well as locator/retention features 144 and 146integrally formed on the reverse (inside) surface of the front plate 70provides a number of significant advantages in the manufacture and finalassembly of the radio/CD player 62 by reducing product part count,assembly time, and substantially eliminates dedicated hard fixturing andtools to affect assembly.

Thermal Management System for Vehicular Radio Application (7)

The thermal devices are placed in a window in the plastic box and areattached to the heat sink, which is attached to the inside of the box.This puts a plastic wall (a good insulator) between the heat sink andthe CD mechanism to minimize the temperature that a CD reaches insidethe box metal case. The thermal efficiency of this system eliminates theneed for a cooling/ventilation fan.

Referring to FIGS. 2-29, 41-43 and 159, an alternative embodiment foraffecting a screwless affixation of a convector or heat sink 252 withina radio/CD player 254 is illustrated. The heat sink 252 and radio/CDplayer are substantially identical to the above-described heat sink 72and radio/CD player 62 in all material respects with the exception ofthe features described immediately hereinbelow.

Referring to FIGS. 22-29, an electrical power device retainer/backingclip 258 is formed of stamped, mild or spring sheet steel and defines agenerally rectangular body portion 258 and three offset support members260, 262 and 264 integrally inwardly and downwardly depending from alower edge 266 of body portion 258. Left and right side retainer clips268 and 270 integrally depend inwardly from left and right side edges272 and 274, respectively, of body portion 258. Left and right heat sinkretainer clips 176 and 278 integrally outwardly extend from an upperedge 280 of body portion. A housing case retaining clip 282 integrallyextends inwardly from the central portion of the upper edge 280.

Radio/CD player 254 has a polymer case 284 in which a port 286 is formedin a left side wall portion 288. Three power circuit components 290, 292and 294 are carried on a common PCB 296 within the case 284 in registerwith the port 286. The power circuit components 290, 292 and 294 aremounted to the common PCB 296 by their respective lead frames which arealigned with a plane defined by the left side wall portion 288. Thus,unlike the power circuit components 118, 120 and 122 described inconnection with FIGS. 2-10 and 15 hereinabove, which are depicted asbeing substantially rigidly affixed to their associated common PCB 98,power circuit components 290, 292 and 294 are laterally displacable dueto bending of their leadframes.

As best viewed in FIGS. 24 and 25, the backing clip 256 is installed bymanipulating it to insert the free ends of the support members 260, 262and 264 into the case 284 through the port 286 above and inwardly of thepower circuit components 290, 292 and 294, respectively. Insertion ofthe backing clip 256 is complete when its lower edge 266 issubstantially aligned with and adjacent the horizontal upper edge of theport 286.

As best viewed in FIGS. 26 and 27, the backing clip 256 is then rotatedclock-wise from the perspective of FIG. 25 to the perspective of FIG.27. Insodoing, the support members 260, 262 and 264 reach behind(internally within case 284) and abut the inside surfaces of the powercircuit components 290, 202 and 294, respectively. Support members 260,262 and 264 act as individual cantilevered leaf springs whichcontinuously urge their respective power circuit components laterallyoutwardly. As the backing clip 256 approaches its installed positionillustrated in FIGS. 26 and 27, its side retainer clips 268 and 270extend within and snap-engage ramped catch openings 298 and 300,respectively, securing the backing clip into intimate contact with theouter surface of the left side wall portion 288 of the case 284.Furthermore, case retaining clip 282 snap-engages a ramped, upwardlyextending retention tab 302 formed on an upper wall portion 304,providing redundant retention with the case 284.

As best viewed in FIGS. 28 and 29, the heat sink 252 comprises a stampedplaner aluminum body 305 with three integral spaced locating tabs 306extending downwardly from the bottom edge thereof and spaced left andright integral locating tabs 308 and 310 extending upwardly from theupper edge thereof. The heat sink body 305 forms a recessed portion 314which, upon installation, extends laterally within the case 284 throughthe port 286.

The heat sink 252 is installed by manipulating it in the positionsuggested in FIG. 28 wherein each locating tab 306 engages itsrespective tab receiving socket 312. The heat sink 252 is then rotatedcounter-clockwise from the perspective and position of FIG. 28 to theinstalled position of FIG. 29. Insodoing, upper tabs 308 and 310 snapengage retainer clips 276 and 278, respectively, positively locking theheat sink in its installed position.

When installed, the inner surface of the recessed portion 314 of theheat sink 252 intimately abuts the outwardly directed (thermal output)surfaces of power circuit components 290, 292 and 294 to provide a heatdissipation path thereto. The resilient support members 260, 262 and 264maintain the intimate contact between the power circuit components 290,292 and 294 and the heat sink 252. If required, thermal grease can beapplied to the inside surface of the recessed portion 314 to improvethermal conductivity.

Referring to FIGS. 41-42, a simplified, alternative embodiment of afastenerless thermal control system for an audio device 316 isillustrated. The audio device 316 includes a case 318 enclosing a PCB320. One (or more) power circuit components 322 have their lead frames324 solder connected to the PCB 320 and is cantilevered therefrom. Aresilient power clip 326 is affixed to the PCB 320 and includes acantilevered resilient leaf spring 328 which continuously bears againstthe inside surface of the power circuit component 322. A heat sink 330has cooperating self-engaging/retaining features with the audio systemcase 318. When in the installed position (FIG. 42) the inside surface ofthe heat sink 330 is in intimate contact with the power circuitcomponent 322, and is retained in contact by the constant urging of theleaf spring 328.

Referring to FIG. 43, the abovedescribed power clip 326 of FIGS. 41 and42 is eliminated and a power circuit component 332 is solder connectedto a PCB by a lead frame 336 comprising both electrically conductivelead elements 338 and a spring-like lead element 340. Spring element 340of the lead frame 336 serves to continuously urge the power circuitcomponent 332 to its illustrated position. When the heat sink 330 isinstalled, the spring lead element 340 will maintain the power circuitcomponent 332 in intimate contact with the heat sink 330.

Referring to FIG. 159, another simplified alternative embodiment of afastenerless thermal control system for an audio device 342 isillustrated. The audio device 342 comprises a case 344 formed ofthermally insulating material. A PCB 346 is disposed within the case 344which has a power circuit component 348 cantilever affixed thereto viaits lead frame 349 positioned adjacent a thermal port 350. Aretainer/backing clip 352 is snap-engaged with a feature 353 on theexterior of the case 344 and includes a resilient integral supportmember 354 extending through the port 350 and continuously resilientlyurging the power circuit component 350 toward the port 350. A heat sink356 snap-engages with features on the case 344 and backing clip 352 toretain it in its illustrated position wherein the power circuitcomponent 348 is maintained in intimate contact with the inner surfaceof a recessed portion 358 of the heat sink 356 extending through theport 350.

Convection air flow (arrows 359) can be provided by providing inlet andoutlet windows 360 and 262 in the case 344. A pocket 364 formed on theouter surface of the heat sink 356 as part of the recessed portion 358can be filled with a thermally conductive material 366 to increase theeffective thermal mass of the heat sink 356 and to improve radiantthermal rejection as indicated by arrows 368.

Low cost Structural Support for CD Changer for Vehicular RadioApplication (8)

Using a plastic box for the receiver enables low cost location andsupport for the CD mechanism and enables for slide lock assembly insteadof the screws used in a traditional receiver. The brackets on the CDmechanism have a 1° taper that matches a 1° taper on the support shelfin the plastic box. This makes it easy for an operator to start theslide, but all of the clearances go to zero as the box snaps into placeproviding a strong rattle free assembly without the use of thetraditional screws.

Referring to FIGS. 30-36, 151, 152 and 160, the details of the mountingof the CD player subassembly 66 within the housing case 68 (refer FIG.3) are illustrated in a simplified form. FIGS. 30-32 represent alongitudinal cross-section of a case guideway 370, including a rear wallportion 372 taken just laterally inside of the right side wall portion(not illustrated) of a housing case 374 to illustrate the spacialcooperation between the case guideway 370 and a right side CD playermounting bracket 376 during the insertion thereof in the assembly of aradio/CD player 378. A minor-image case guideway is integrally formed onthe opposite, left wall portion of the case 374.

The guideway 370 is integrally formed with the right sidewall portion(not illustrated) and the rear wall portion 372 of the housing case 374,projecting laterally therefrom. The guideway 370 is generally “C”shaped, having laterally disposed upper and lower leg portions 380 and382 extending longitudinally the entire depth of the case 374. The legportions 380 and 382 form continuously converging or tapered surfaces384 and 386, respectively, which are offset by an angle α (nominally 1°)vertically centered above and below a longitudinal assembly axis 388.The mounting bracket 376 is preferably stamped from sheet aluminum orsimilar material and is also generally “C” shaped, having a verticalportion 390 and laterally disposed upper and lower leg portions 392 and394 extending longitudinally substantially the entire depth of the case374. The leg portions 392 and 294 form continuously converging ortapered surfaces, respectively, which are offset by an angle φ(nominally 1°). The mounting bracket 376 has a leading edge surface 400which, upon assembly, approaches the inside surface 402 of the case rearwall portion 372. The vertical portion 390 of the mounting bracket 376has a rearwardly directed integral tab 404 extending from edge surface400. The tab 404 has a localized upset bead or rib 406.

The CD player subassembly is installed by manually aligning the leadingedge surface 400 of the mounting brackets 376 with the opening 408 ofthe guideway 370 (refer to FIG. 30) and rearwardly displacing it alongthe assembly axis 388. FIGS. 31 and 151 illustrate a mid-point in theinsertion process wherein the guideway surfaces 384 and 386 remainsubstantially parallel to the cooperating mounting bracket surfaces 396and 398. The guideway serves to register, align and guide the insertionof the mounting brackets 376. As the CD player subassembly 66 approachesthe installed position depicted in FIGS. 32 and 152, the guidewaysurfaces 384 and 386 contact the mounting bracket surfaces toeffectively provide a zero-tolerance interfit therebetween. This ensuresprecise positioning and effectively eliminates squeaks and rattles inapplication. As best viewed in FIGS. 32-36, in the installed position,the tabs 404 slip-fit penetrate into an opening or recess 410 in rearwall portion 372. The upset rib 408 forms an interference-fit within thewindow 410 to lockingly engage the CSD player subassembly 66 within thecase 374.

Referring to FIG. 153, an alternative mounting configuration of aninstalled CD player subassembly 412 within a housing case 414 isillustrated. A sidewall 416 of the case 414 integrally defines aguideway 417 which extends laterally outwardly to form facing acutelyoffset cooperating upper and lower guide surfaces 418 and 420,respectively Likewise, the CD player subassembly 412 carries left andright mounting brackets 422 (only one is illustrated) having acutelyinwardly angled upper and lower legs 424 and 426, respectively, definingupper and lower surfaces 428 and 430, respectively.

Referring to FIG. 154, an additional alternative mounting configurationof an installed CD player subassembly 432 within a housing case 434 isillustrated. A sidewall 436 of the case 434 integrally defines aguideway 438 which extends laterally inwardly to form opposed acutelyoffset cooperating upper and lower guide surfaces 440 and 442,respectively. Likewise, the CD player subassembly 432 carries left andright mounting brackets 444 (only one is illustrated) having acutelyoutwardly angled upper and lower legs 446 and 448, respectively,defining upper and lower surfaces 450 and 452, respectively.

A localized area of wire screen 454 can be formed in the guideway 438 toaffect a ground path between the CD player subassembly 432 and the case434.

Referring to FIG. 160, an alternative guideway 456 for the CD playermounting bracket 376 (refer FIGS. 30-32) has upper and lower legportions 458 and 460, each having a tapered, increasing thickness in thevertical dimension along their longitudinal extent (along the assemblyaxis 462. Upper and lower guide surfaces 464 and 466, respectively, areoffset by angle α. Outer guideway edge surfaces 468 and 470 have aslight reverse taper at an offset angle ε (approximately 1°-3°) toprovide release draft for the injection molding process.

Wire Mesh for Structural Component (9)

Molding in metal mesh into the plastic receiver case and front plateincreases the strength of the material (much like putting re-bar intoconcrete) while still weighing less than a steel case. The gauge of thewire forming the mesh can be increased and the amount of plasticmaterial can be substantially reduced, resulting in a very thin wall,robust structure.

As an alternative to the structure illustrated in FIG. 37, the plasticcan be eliminated from the center portions of some or all of theindividual side, front, back, top and/or bottom panel portions of thecase and front plate. This configuration would have the appearance of ascreen box, with a molded plastic peripheral frame circumscribing eachpanel portion.

Referring to FIGS. 37, a lightweight automotive audio system 471 caninclude a housing case 472 constructed of a composite of polymer basedmaterial with a wire screen 474 insert molded therein to isolate audiocomponents therein from various electrical anomalies. To further reduceoverall weight, the gauge of the wire screen can be increased wherebythe screen contributes a significant component of the resulting overallstructural strength of the case, while the nominal section or thicknessof the polymer material can be substantially reduced. By way of example,the case 472 top and bottom wall portions 476 and 478, respectively, andleft and right side wall portions 480 and 482, respectively, injectionmolded into a single unified structure, with the enlarged gauge wirescreen 474 insert molded adjacent the inner surfaces thereof. Edges andcorners of the case 472 formed at the intersection of two or threeadjacent wall portions can be locally thickened to increase structuralrigidity of the case 472 as well as to provide internal and externalmounting and interface ports. The intersecting edges of the top wallportion 476 and the left and right side wall portions 480 and 482,respectively, form thickened left and right upper edge frames 484 and486, respectively. Likewise, the intersecting edges of the bottom wallportion 478 and the left and right side wall portions 480 and 482,respectively, form thickened left and right lower edge frames. Loweredge frames 488 and 490 are locally vertically extended openings 492 and494 for exposing the wire screen 474 to establish electrical contactwith contact clips 496 and 498 carried by PCBs 500 and 502,respectively, interconnected by pin connectors 504 within the case 472.

Referring to FIG. 150, the example embodiment of FIG. 37 is furthermodified to form an extremely lightweight case 506 constructed ofpolymer based material and wire screen 508. Case 506 is configured sothat some or all of the wall portions comprise a polymer frame 510 aboutthe perimeter thereof and the wire screen 508 closing the center portionof such wall portions. Portions of the wire screen 508 adjacent edges ofthe case 506 are affixed to the frame 510 such as by insert molding.Attachment features such as mounting flanges 512, tab receivingextensions 514, ramped snap-engagement features 516 can be molded as anintegral portion of the frame 510. Ports, such as wiring harnessinterconnections 518 and 520, and coaxial cable antenna interconnections522 can be easily molded within an extended frame portion 524. Windows526 and 528 can also be formed in extended frame portion 524 forelectrically interconnecting the wire screen 508 with internalcomponents.

Flexible Molded Linkage for Rear Loaded Pushbuttons (10)

This concept is disclosed in U.S. Pat. No. 6,384,355 B1 to M. Murphy etal. entitled “Parallel Guide Mechanism for a Switch” which is commonlyassigned to the assignee of interest of this application. Thespecification of U.S. Pat. No. 6,384,355 is hereby incorporated hereinby reference.

Living Hinge Button Linkage (11)

The basis of 4-bar button linkage is described in U.S. Pat. No.6,384,355, the specification of which is incorporated herein byreference. It utilizes thin walls on each end of a base and top plate tocontrol the motion of a button. However, this approach allows the buttonto slightly rotate if someone presses on the extreme left or right edgeof the button. The living hinge is an improvement/modification of theidea where the thin walls are replaced with relatively thick walls,which are necked down at the intersection with the button and the topplate to form a living hinge and complete the 4-bar linkage. Thisconcept can be applied in a treed button system.

In essence, the thin wall approach results in flexing or deformation ofthe wall, which will produce variations in the spacing between theassociated hinges of each link. This can cause wobble or relative motionbetween the portion of the button extending through an opening in theuser access panel. If the spacing tolerance between the button and theadjacent access panel opening is excessively small, the button can jamand cease to function. If the spacing tolerance is too great, it canresult in undesirable squeaks and rattles.

In the present invention, the links are relatively inflexible (except inthe integral hinge area), resulting in the spacing between the adjacenthinges to remain substantially constant. This will provide a smooth,substantially linear motion of the button, mitigating the under and overtolerance problems of certain prior art approaches described hereinabove.

Referring to FIGS. 44-47, an example of prior flexible molded linkagefor rear loaded pushbuttons is illustrated. A pushbutton linkage system530 includes a base member 532 and a top plate 534 spaced above the basemember 532 and integrally interconnected thereto by front and rearvertical members 536 and 538, respectively. The front and rear verticalmembers 536 and 538 have a thin wall section along their vertical extentand are relatively flexible. The top plate 534 has an extension 540formed therein which, in application, extends through an opening 542within a panel 544 such as a radio trim panel to provide operator accessby manual actuation as indicated by arrows 546, 548 and 550. The pushbutton linkage system 530 is typically nested within a switch housingassembly 552 consisting of a rigid housing portion 554 and resilient,non-conductive material 556 which maintains spacing between a fixedelectrical contact and a movable electrical contact (not illustrated).When the extension 540 is depressed by an operator, the top plate 534moves to the left, momentarily closing the two electrical contacts. Whenreleased, the top plate 534 returns to its illustrated position, openingthe electrical contacts. When actuated along the centerline of the topplate 534 designated by axis X-X as indicated by arrow 546, it willtranslate left and right, without pitch or yaw. However, if actuatedfrom an off center direction as depicted by arrows 548 and 550, it willpitch and/or yaw, as illustrated by axis X′-X′ due to the flexure of thedistributed displacement of members 536 and 638 as best seen in FIG. 47.As a result, the associated switch mechanism can malfunction due tobinding between the extension 540 and the panel 544.

Referring to FIGS. 48-50, a simplified embodiment of the presentinvention is illustrated. A push button linkage system 558 comprises anelongated, horizontally disposed base member 560 and an elongated,horizontally disposed top plate 562 positioned above and parallel to thebase member 560. Front and rear vertical links 564 and 566 interconnectthe front and rear ends of the base member 560 and the top plate 562,respectively. The base member 560, top plate 562 and interconnectinglinks 564 and 566 are integrally molded or extruded as a singlecomponent from homogeneous, relatively rigid material such as nylon. Thefront link 564 defines a relatively thick sectioned middle portion 568,upper and lower end portions 570 and 572, respectively, and intermediatetransition portions 574 and 576. Likewise, the rear link 566 defines arelatively thick sectioned middle portion 578, upper and lower endportions 580 and 582, respectively, and intermediate transition portions584 and 586.

The upper end portion 570 of the front vertical link 564 integrallytransitions into the bottom front corner of the top plate 562 as a webor first flexible living hinge. The upper end portion 580 of the rearvertical link 566 integrally transitions into the bottom rear corner ofthe top plate 562 as a web or second flexible living hinge. The lowerend portion 572 of the front vertical link 564 integrally transitionsinto the top front corner of the base member 560 as a web or thirdflexible living hinge. The lower end portion 582 of the rear verticallink integrally transitions into the top rear corner of the base member560 as a web or forth flexible living hinge. Thus constituted, the pushbutton linkage system 558 comprises four rigid links arranged as aparallelogram with their respective adjacent ends attached at hingepoints.

In application, the linkage system is nestingly received within a switchassembly 588 including a housing 590 which fixedly restrains the linkagebase member 560 and means for continuously urging the linkage top platerightwardly toward its position depicted in FIG. 48 such as a resilient,elastomeric foam block 592. A pair of switch contacts 594 and 596 arealigned within the switch housing 590, with one contact 594 fixed to aninner surface 598 of the housing 590, and the other contact 596 carriedon a rear edge surface 599 and movable with the linkage top plate 562between an open position, spaced from contact 594 (FIG. 48) and a secondposition engaging the other contact 594 (FIG. 49) to establish anelectrical interconnection therebetween.

The front end of the linkage top plate 562 forms an integral rightwardlydirected extension 600, which passes through an opening 602 formed in apanel 604 such as the trim plate subassembly 74 described in connectionwith FIG. 3 hereinabove. Manual displacement of the extension 600indicated by arrow 606 causes the living hinges to affect pure rotationabout their mutually parallel axes, transitioning the top plate 562 (andmovable contact 596) to the position indicated in FIG. 49.

Empirical development and analysis has demonstrated that a switchassembly 588 with the linkage system 558 described herein issubstantially impervious to off-angle actuation.

Referring to FIG. 50, a plurality of switch assemblies 588 can be gangedto form a compact, multi-function control panel such as the trim panel74 in FIG. 3. The linkage system 558 can be expanded for multi-switchapplications by lateral extension of a common base member 560 to supportmultiple sets (4 are depicted) of spaced top plates 610 a-d separatelyinterconnected to common base member 560 via respective front verticallinks 612 a-d and rear vertical links 614 a-d. Each top plate 610 a-dhas an extension 616 a-d, which register with similarly spaced openings618 a-d in a common panel 619. Each of the four linkage systems depictedin the ganged linkage systems 620 in FIG. 50 function independently ofone another, although various electrical interconnections of therespective contact pairs (not illustrated) can be configured tointeract. Although fully functional as described, the extensions 600 and616 a-d are preferably configured to receive, support and illuminatedecorative, indicia bearing front loaded actuator buttons as describedin connection with the device of FIG. 170.

Slide-Lock Snap-Lock Screwless Assembly Method (13)

Using plastic for a receiver case enables low cost assembly of thecomponents. The circuit boards and the CD mechanism can slide into placeand then be locked or they can be snapped into place without screws.This reduces the number of parts required in the assembly and reducesthe amount of direct and indirect labor to put a receiver together. Theplastic case can be easily molded into a net shape forming the slidesand snaps needed for assembly.

Referring to FIGS. 2-10 and 22-29, the apparatus and assembly methoddescribed substantially reduces the labor and component cost of theradio/CD player 62, as well as the required capital costs. Furthermore,it substantially enhances product quality by substantially eliminatingthe possibility of extraneous or missing (small) parts and/or improperassembly.

EMC, RFI, BCI, ESD Wire Mesh Protection System (14)

Using the molded in metal mesh in the receiver plastic box that isgrounded to the circuit boards creates a Faraday cage that providesshielding protection for RFI (Radio Frequency Interference), EMI(Electro Magnetic Interference), BCI (Bulk Current Injection), and ESD(Electrostatic Discharge).

Refer to FIGS. 16 and 37 and their associated descriptions.

Partitioned Main Board into Common and Unique (15)

Using the principle of communization and modularity, the receiver mainboard has been divided into a common board and a unique board. This iscounterintuitive because a single board is less expensive than twoboards performing the same function. However, the common board containsall surface mount components (no stick lead or wave solder) and verylarge volumes can be produced without reconfiguring theassembly/production line. This will substantially reduce themanufacturing cost of this portion of the main board.

Referring to FIG. 15, automotive audio systems are unique in that theyare typically designed in modular form and, in response to therequirements of individual customers, are produced by assemblingindividual units from varied combinations and permutations ofmodularized subcomponents. This, however, can be contrary to themanufacturing doctrine of large enterprises wherein large volumeproduction of common designs is preferred for its inherent efficiencies.In the practice of the present invention, the individual electricalcomponents to be assembled on the circuit board subassembly 64 aresegregated into those which will be employed in each specie andsub-specie in a given product family. The commonly employed circuitelements (typically surface mount devices) are assembled on the “common”PCB 98. The application specific circuit elements (typically “stick”mount devices) are assembled on the “unique” PCB 100. The common PCB 98is assembled employing highly automated manufacturing techniques formaximum efficiency, while the unique PCB 100 are assembled employing adifferent mix of labor and automation to maximize overall efficiency.Standard connector assemblies 736, 738 and 740 are provided on thecommon PCB 98 for interfacing the radio/CD player 62 with speakers,ground, power and associated control/readout systems via wire harnesses.A standard coaxial cable connector 742 is also provided on the commonPCB 98 for interfacing with a vehicle antenna system.

An audio product manual entitled “2004 Model Year Ford Freestar Radios”(Document Number 04-RDPD-12-MA-F), dated 7 Oct. 2005, describes indetail the circuit architecture of a family of modern automotive audiosystems developed and produced by the assignee of this application. Inaddition, the manual enumerates the individual electrical componentsemployed and their arrangement in various audio subsystems. In thepractice of the present invention, the listed individual electricalcomponents would be segregated into the common PCB 98 and unique PCB 100in keeping with the teachings herein. Accordingly, the above referencedaudio product manual is incorporated herein by reference for the sake ofcompleteness and to serve as a resource in understanding and practicingthe present invention.

Referring to FIG. 164, an alternative embodiment of an audio system 1622has a one-piece plastic housing 1624 defining a rear wall portion 1626and a bottom wall portion 1628. Rather than providing discrete connectorassemblies, such as assemblies 736, 738 and 740 in FIG. 15, with eachincluding an insulating shell portion and a number of connector pinsaffixed to the PCB 98, an insulating shell is eliminated for eachconnector and replaced by an outwardly opening niche or pocket 1630integrally formed on one of the case wall portions (for example, therear wall portion 1626). Associated connector pins 1632 are affixed to aPCB 1634 and extend through registering openings 1636 in a case wall1638 segment forming the niche 1630 in a direction parallel to anassembly axis 1640. The case wall segments 1638 defining the niche 1630also include integral attachment features for the mating wiring harnessplug (not illustrated). This feature reduces part count and cost whileconserving space within the audio system housing assembly.

Fault Codes to Replace In-Circuit Test (16)

In the present invention, a form of “self test” is employed and thenormal in-circuit test with its expensive fixtures, long test cycle timeon expensive equipment is replaced by a simple fixture that powers upthe microprocessor and activates embedded test codes that asks the microto communicate with each of the other ICs on the board and return anyfault codes. This is a much lower cost approach, which will accomplishmost of the benefit of an in-circuit test.

Referring to FIG. 55, prior manufacturing of automotive audio devicestypically employed dedicated test equipment located at the end of anassembly line which serially initiated, ran, completed and recordedperformance tests for each unit before initiating testing of thenext-in-line unit. Such prior art testing sequences typically followedthe following process steps. The test is initiated at step 744, thetester performs a fault test at step 746 for a first integrated circuit(IC) 748. After waiting for and recording the IC#1 test results, thetester advances to step 750 and performs a fault test for a second IC752. After waiting for and recording the IC#2 test results, the testeradvances to step 754 and performs a fault test for a third IC 756. Afterwaiting for and recording the IC#3 test results, the tester advances tostep 758 and performs a fault test for a forth IC 760. After waiting andrecording the IC#4 test results, the tester proceeds serially to testevery additional IC in the unit under test. Once all of the ICs havebeen tested and the results recorded, the test is terminated at step762.

Referring to FIG. 56, the present invention saves substantial time inend-of-line testing by embedding the test routines within the memory andmicroprocessor contained within the audio unit being tested. This allowssimultaneous testing of multiple audio units and virtually eliminates“wait-time”. The testing sequence of the present invention follows thefollowing process steps. The test is initiated at step 764 and thetester sends a “start test” message to the audio product at step 766which initiates a subroutine in an on-board microprocessor for faulttesting other ICs within that audio product at step 768. The on-boardtesting performs fault tests and collects results for each IC 770, 772,774 and 776 within the audio product at step 778. Thereafter, theaccumulated test results for the audio product are sent to theproduction line tester at step 780. Immediately following step 766, thetester immediately sends a “start test” message to the next audio unitin the production queue at step 782 without waiting for the results ofpreviously initiated tests. This testing technique continues as long asthere are audio products in the manufacturing queue to be tested. Whenthe queue is empty, the testing is ended at step 784.

WWV Time Set for Radio (17)

In the alignment of a radio, one of the steps taken is to calibrate thelocal oscillator. This is done by comparing the natural frequency of theoscillator to a known standard and recording the difference as anoffset, which is stored in memory and is used to make sure the clock isaccurate.

Referring to FIG. 57, a typical prior art process for calibrating thelocal oscillator of an automotive radio comprises the steps of measuringthe resonator frequency at the point of manufacture at step 786.Thereafter, an offset value reflecting the difference between the radiooscillator and a known standard is calculated at step 788. Finally, thecalculated offset value is programmed into memory of the specificautomotive radio at step 790. Thereafter, once the automotive radio isinstalled in a host vehicle and is in the field, the radio reads theoffset value from its internal memory at step 792. Lastly, theautomotive radio periodically updates its time of day display based uponthe read offset value at step 794.

In the present invention, the need for a known standard and running thistest at all in the factory is eliminated. The radio will be programmedto tune to WWV on 100 KHz periodically and use their calibrationfrequency as the known standard for calculating the offset. The correcttime will also be updated when this takes place.

Referring to FIG. 58, a simplified process for easily and reliablyupdating the time of day indication for an automotive radio isdescribed, involving receiving a time of day signal from a World TimeClock at step 796 and then periodically updating the time of dayindication of the automotive radio in response to the time of day signalfrom the World Time Clock.

Devices such as automotive radios/CD players use a low cost resonatorcircuit to provide a reference frequency for the Time of Day (TOD)Clock. Due to inherent inaccuracies in this resonator frequency,periodic adjustments must be made to the TOD to retain it's accuracy.Previously, during the production process, the frequency of theresonator is measured and it's actual value is compared to an expectedvalue. This difference is then stored into product memory and the TODclock is periodically updated. This method requires a special processduring production (i.e. a high capital investment) to measure theresonator frequency. In the present invention, during normal operation,the receiver can periodically tune to the World Time Clock (WWV) andreceive a time signal. This time signal can then be used to update theTOD clock. This inventive method does not require a specialmanufacturing process and can be accomplished using existing producthardware design.

The accuracy of a free running clock is limited by accuracy of theunderlying crystal. A 25 ppm (parts per million) error in crystalfrequency results in over a minute error per month for a clock. Thetraditional solutions are to either purchase expensive high accuracycrystals or to align the crystal circuit for each individual unit.Alignment can be by either physically adjusting the crystal circuit orby providing a frequency offset to software. Either case requires highlyaccurate measurement of the actual circuit frequency. Additionally,alignment only corrects the nominal crystal error. It does notcompensate for temperature or age drift.

An alternate solution is to use a cheaper, lower accuracy, unalignedcircuit to maintain the running time and to periodically correct thetime setting by referencing an external highly accurate clock. WWVprovides such an external signal on multiple radio frequencies. Theunique part of this solution is the shared use of a general purposeAM/FM receiver block with a method to avoid the disruption of the use ofthe tuner and minimize the use of standby current.

The algorithms illustrated in FIGS. 87-89 collectively allow a singletuner to be used both as a general purpose AM/FM receiver and tomaintain the accuracy of a free running time of day clock. It alsoaffects minimal current draw when the unit is battery powered.

The controlling factors for determining when to update the clock are theminimum update time and the maximum update time. For a typical clockthat displays minutes, these two times should be less than the time forthe worst case drift of the running timer to accumulate 15-20 seconds oferror. The minimum update time limits the rate of updates to minimizepotential disruptions and current usage. The time limit should be setbased on the time for the free running timer to accumulate significanterror (e.g., 5 seconds of drift). If the radio is already in a highcurrent operational state and the timer is not in use (for example, theradio is in CD mode), an attempt to update the time occurs immediately.The update is also delayed, if the tuner is currently being used (i.e.,the user is listening to an AM or FM broadcast). If the radio is in alow current state, a time update attempt is delayed until the maximumupdate time is exceeded.

Referring to FIG. 87, a process for updating the time of day indicationof an automotive radio comprises the steps of initiating a time of dayindication update at step 800. Initially, a logical step 802 determinesif a minimum time since the last update has expired. If no, the processis ended at step 804. If yes, process moves to a logical step 806 whichdetermines if the ignition in “on”. If no, the process moves to alogical step 808 which determines if the maximum time since the lastupdate has expired. If no, the process is ended at step 804. If yes, thetuner is powered up at step 810. If the ignition is on, the processdetermines if the tuner is presently in use at logical step 812. If yes,the process is ended at step 804. If no, the radio tunes to a known WWVfrequency at step 814. Thereafter, the process moves to a logical step816 which determines if a valid time signal is present. If no, itdetermines if there are alternative frequencies left and there is nouser request at the tuner at logical step 818. If yes, the processreturns to the input of step 814. If no, the process is ended at step804. If a valid time signal is present, the process updates the freerunning time at step 820. If the free running time update is successful,the process saves the time of the last update at step 822. If the freerunning time update is not successful, the process is aborted and endedat step 804.

A dual level of service can be provided. As illustrated in FIG. 88, thefirst level requires the user to manually set the time and simplycorrects for drift of the free running timer. This requires the tuneronly to be able to detect a 440-600 Hz tone present at the top of theminute. The update of the free running timer simply rounds the currenttime value to the nearest minute. This provides equivalent functionalityas a clock based upon either a high accuracy or aligned crystal basedsystem.

The simple drift correction process of FIG. 88 begins at step 824 andmoves to logical step 826 which determines if there is a user requestfor the tuner. If yes, the process is aborted and exits at step 828. Ifno, the process moves to logical step 830 which determines if a top ofthe minute tone is present. If no, the process returns to the input oflogical step 826. If no, the process rounds the free running time to thenearest minute at step 832. The process then exits with an update atstep 834.

As illustrated in FIG. 89, the second level of service is to actuallyset the clock based on BCD encode time information in the WWV signal.This method requires a more sophisticated decoder to detect the 100 Hzsub-carrier and decode the time information encoded in the sub-carrier.On each update, non-volatile offsets for hours and minutes would beadded to the received values to compensate for time zones and user“adjustments”. The user would still have to have a method to adjust thehours for setting the time zone. Optionally, the system could allow theuser to adjust the minutes offset, for people who wish to run theirclocks fast or slow on purpose. The primary advantage of this approachis that if the running time value is lost (for example, after a batterydisconnect), the clock will recover with the correct time at the nextupdate. Furthermore, the clock will automatically adjust for daylightsavings changes.

Referring to FIG. 89, an exact time of day correction is initiated atstep 836 and thereafter moves to a logical step 838 which determines ifthere is a user request for the tuner. If yes, the process aborts andexits at step 840. If there is no user tuner request, the process movesto a logical step 842 which determines if the decoding of the BCD timesignal is complete. If no, the process is returned to the input oflogical step 838. If yes, the process adds user offsets to the hours andminutes settings at step 844. Thereafter a free running timer value isset at step 846. Finally, the process exits with an update at step 848.

Guillotine Heat Sink (18)

The guillotine heat sink uses a flat aluminum plate as a heat sink. Itslides down a slot on each side of the plastic box until it comes torest on the quad bridge amplifier (QBA) IC and the power supply IC. EachIC will have a silpad on top to provide compliance and facilitate heattransfer. A downward force will be applied to the heat sink through amolded leaf spring in the lid of the plastic bob when it is snapped intoplace. An additional feature of the plastic box is to provide pillarsunder the FR-4 board in the location of the power ICs to provide abackstop for the leaf spring force.

Referring to FIGS. 38-40, a fastener-less electronic device 850 includesa housing assembly 852, an electrical assembly 854 and a heat sinkstructure 856. The housing assembly 852 comprises a generally box-likecase 858 and a closure member 860. The case 858 and closure member 560form guideways for positioning and supporting the heat sink 856 andelectrical assembly 854.

In the illustrated embodiment, the case 858 and closure member 860 areformed of polymer based material. The case 858 includes left and rightside wall portions 862 and 864, respectively, a lower wall portion 866 arear wall portion 868 and a front wall portion (not illustrated)substantially similar to the rear wall portion 868 in configuration andfunction. The case 858 includes ramped, outwardly extending features 870integrally formed on outside wall surfaces 872 which cooperativelyengage catch features 874 integrally formed on edges 876 of the closuremember 860 which snap-lock with the ramped features 870 to affecttool-less, fastener-less assembly of the case 858 and closure member860.

Longitudinally extending inwardly opening guideways or slots 878 and 880are formed in the lower portion of the left and right sidewalls 862 and864 for slidably receiving edge surfaces 881 and 883 of a carrier 882such as a PCB. First and second heat generating electrical components884 and 886, respectively, are mounted to the upper surface 888 of thePCB 882. Localized pillars 890 and 892 are integrally formed in thelower wall portion 866 defining upper abutment surfaces 894 and 896,respectively, supporting the lower surface 898 of the PCB 882 inlocations registering with the electrical components 884 and 886.

Vertically extending inwardly opening guideways or slots 900 and 902 areformed in the left and right case sidewalls 862 and 864 for slidablyreceiving edge guide surfaces 904 and 906, respectively, of the heatsink 856. Slots 900 and 902 are longitudinally aligned with theelectrical components 884 and 886 as well as the pillars 890 and 892.The heat sink 856 is substantially planer and formed of aluminum. Theheat sink has a bottom edge 908 including two integrally formedextensions 910 and 912, respectively which laterally register with theelectrical components 884 and 886, respectively. The heat sinkextensions 910 and 912 are configured to either bear downwardly againstthe exposed upper heat liberating surfaces of the electrical components884 and 886 or, alternatively, can support “silpads” or similar thermalcoupling devices 914 and 916 therebetween.

A leaf spring 911 is integrally formed within an opening 913 in closuremember 860. The leaf spring 911 extends as a cantilever downwardly belowa lower surface 918 of the closure member 860. The leaf spring 911 iselongated along an axis that extends laterally and in register with atop edge 920 of the heat sink 856.

The electronic device 850 is assembled simply by manually engaging theedge surfaces 881 and 883 of the PCB 882 of the electrical assembly 854within the slots 878 and 890 and displacing it rearwardly into itsillustrated design position. Next, the edge surfaces 904 and 906 of theheat sink 856 are manually positioned in their respective vertical slots900 and 902 and the heat sink lowered “like a guillotine” until itsextensions 910 and 912 abut their respective heat generating components884 and 886 (possibly with an intermediate silpad 914 and 916). Theclosure member 860 is then manually snapped into its illustratedassembled position wherein the leaf spring 914 continuously bearsdownwardly against the top edge 920 of the heat sink 856 for radiatingheat away from the heat generating components 884 and 886.

Button Tree Concept (19)

In the button tree concept, as many buttons as possible are treedtogether in the molding process to reduce handling of buttons insubsequent operations. The paint fixture will be placed on a machinethat singulates the tree and transfers the buttons to the trim plate.Buttons are currently molded one-up and must be placed in the paintfixture one at a time and then transferred to the trim plate one at atime.

Referring to FIGS. 51-54 and 170, a method and apparatus for efficientlyfabricating push buttons and assembling the push buttons on associatedindividual actuator devices, such as the switch assemblies described inconnection with FIGS. 48-50 herein, as part of an automotive audiosystem assembly is described hereinbelow.

Overall, the inventive process is outlined in FIG. 51 in a number ofprocess steps including initiating the process at step 922, molding aplurality of buttons as a set or subset on a common tree or gate withthe individual buttons positionally juxtaposed in an end-applicationorientation at step 924, inserting the button (sub)set into a paintfixture in an end-application orientation in step 926, painting selectedsurfaces of each button of the (sub)set of buttons while in the fixtureat step 928, trimming extraneous material from each button at step 930,singulating the buttons of the (sub)set by removing the common treewhile maintaining them in fixed juxtaposition at step 932,simultaneously front loading the (sub)set of buttons through assignedend-application apparatus trim plate openings associated with theassociated individual actuator devices at step 934, and ending theprocess at step 936.

Referring to FIGS. 52-54, a simplified application of the presentinventive concept is described for the sake of clarity. FIG. 52represents a standard automotive radio receiver 938 including a fronttrim plate 940 and various operator controls and displays such as anon-off-volume and treble-bass control 942, a tuning and speaker balancecontrol 944, an liquid crystal (LCD) display 946 and a ganged array ofpush buttons 948-958. Each of the push buttons 948-958 are front mounted(i.e. applied to trim plate 940 of the radio receiver 938 from thefront) engaging individual associated actuator devices (not illustrated)located behind the trim plate 940.

The typical prior approach of producing such a receiver would entaileither individually injection molding each of the push buttons ormolding them on a common tree, but with no regard to their relativejuxtaposition during the molding process vis-à-vis their relativejuxtaposition in their end application. This is because the individualpush buttons are typically immediately separated from their common treeand thereafter handled and processed separately.

The present invention, in essence, maintains a set or subset of buttonsdestined for a common end application in a fixed juxtipositionalrelationship corresponding to their end application design arrangementfrom their initial formation during the molding process, throughtrimming, decorating, painting, finishing, singulation (i.e. removalfrom their tree/gate) and installation in an end-application apparatus.

Referring to FIGS. 52-54, for purposes of the present example, it isassumed that the dimensional constraints and layout of the push buttons948-958 in the radio receiver 938 prohibit simultaneous molding of allsix push buttons 948-958. A preferred option, then, is to separatelyinjection mold two subsets of push buttons. A first subset 960containing alternating push buttons 948 (“A”), 952 (“C”) and 956 (“E”),connected by a common tree/gate 962, is illustrated in FIG. 53. A secondsubset containing alternating push buttons 950 (“B”), 954 (“D”) and 958(“F”), connected by a common tree/gate, is not illustrated. Asillustrated in FIG. 54, the two subsets of push buttons areinterdigitated to assume their end-application orientation when placedin a processing fixture 964. The push buttons remain in the fixture intheir relative end-application orientation through all of theabove-described processing steps. As a final step, automated equipmentsimultaneously removes the six push button set from the processingfixture 964 and simultaneously installs them in the radio receiver 938.In addition to substantially reducing labor cost, this novel processvirtually eliminates improper assembly of the push buttons and manyother common quality related issues.

Referring to FIG. 170, a single front loaded color shifting push button966 is illustrated in an installed position on a back loaded actuatorcontrol member 968 extending through an opening 970 in a trim panel 972of an audio device 974. The core 976 of push button 966 is formed ofclear material suitable for back-illumination by a light emitting diode(LED) 978 mounted axially within the control member 968. Prior to finalassembly, the push button 966 is processed as described hereinabove,including the application of overlayments of a light diffusing layer980, a light fluorescing layer 982, a coloration under-layer 984, and adecorative opaque topcoat 986 forming decorative indicia and clear ortranslucent light transmitting regions 988. It is also contemplated thatother related process steps, such as dual or tri-shot, multi colorinjection molding techniques and second surface decorative finishing canbe employed within the present invention.

Screwless Power Clip (20)

The screwless power clip is an extension of a clip that Grundig uses inautomotive radios produced in Europe today. The Grundig clip uses a longlever arm that must be snapped after the PCB is assembled into the metalwrap around. This requires an operator to reach in with a tool and snap(distend and release) the clip.

In the present invention, the long lever arm is eliminated. The presentinvention uses the assembly action of hooking the bottom of the heatsink into plastic stirrups and rotating the top of the heat sink untilit snaps at the top of the plastic box to provide the lever action. Thisassembly technique can be accomplished by an operator without the use ofexpensive or specialized tools.

An additional approach to this idea is to eliminate the clip altogetherand to employ a spring material as part of the lead frame.

Refer to FIGS. 41-43, described hereinabove.

Adjustable Shelf Case

In this mechanical configuration the case starts out as a sheet metalsleeve. Plastic inserts for the left and right side are then snappedinto place that contain/define slides for the circuit boards and for aplastic shelf that would hold the CD mechanism at the proper height forregistering with its associated CD slot. The back of the receiver wouldbe an aluminum plate guillotine heat sink that slides in slots in theback of the plastic inserts.

Referring to FIGS. 59-69, an automotive audio system 990 is configuredto be hand assembled and is virtually fastener-less. Furthermore, thisembodiment is easily reconfigurable, both at the time of originalmanufacture and later in service life to facilitate field repairs andchange-over to upgraded technology. The audio system comprises a simplesheet metal housing sleeve 992 defining left and right side walls 994and 996, respectively, a bottom 998, a top 1000, and front and rearopenings 1002 and 1004, respectively. Plastic inserts 1006 and 1008 aresnap-engaged adjacent the inner surface of the left and right walls 994and 996, respectively, within the sleeve 992 by a system of resilienttabs 1010 integrally formed as cantilevers within inserts 1006 and 1008and cooperating locking holes 1012 formed in the top 1000 and bottom 998of the sleeve 992. Each resilient tab 1010 includes a verticallyextending pin 1011integrally formed thereon. The inserts 1006 and 1008have a plurality of vertically spaced, longitudinally extendingmirror-image slots and grooves 1014 formed therein for receiving audiocomponents such as a radio receiver circuit 1016 carried on a PCBassembly 1018, and a CD player subassembly 1020 carried within a ventedinner sleeve 1022. The sleeve has a vertically disposed heat shield 1024affixed to the rear surface thereof which, in assembly, bifurcates thecavity defined by the sleeve 992 into a relatively warm rear portioncontaining the heat generating electrical power devices 1026 on the PCBassembly 1018, and a relatively cool front portion containing the CDplayer subassembly 1020 as well as the low power electrical componentson the PCB assembly 1018. A trim plate subassembly 1028 snap engages thesleeve 992 to close the open front end 1002.

Referring to FIGS. 59-66, a modified “guillotine” type heat sink 1030closes the open rear end 1004 of sleeve 992 by sliding verticallydownwardly through a recess 1034 formed in the rear portion of thesleeve 992 and edge engaging vertical slots 1036 formed in the inserts1006 and 1008. The heat sink 1030 forms convection air cooling openings1038, audio system interconnection ports 1040, and electrical powerdevice attachment passages 1042 therein. The attachment passages 1042register with their respective electrical power devices 1026 whoseprofile outlines are indicated in phantom at 1044. The electrical powerdevices are attached to the inside surface 1040 of the heat sink 1030 byscrews (not illustrated) extending inwardly through passages 1042 oralternatively, by other screw-less resilient means as describedelsewhere herein. Ports 1040 register with audio system connecterassemblies 1048 carried on the rear portion of the PCB assembly 1018.

FIGS. 60-64 illustrate the structural detail of the right side insert1008. The slots 1014 are equally dimensioned and equally verticallyspaced whereby the side edges of the PCB assembly can longitudinallyslide therein. The CD player subassembly retaining inner sleeve 1022 hasconvection cooling passages 1050 in the top surface thereof andparallel, longitudinally extending guide bosses 1052 projectinglaterally outwardly from the sleeve left and right side walls to engagethe slots 1014 in the inserts 1006 and 1008.

The heat sink 1030 form left and right vertical edge surfaces 1054 and1056, respectively. The edge surfaces 1054 and 1056 define opposed uppersteps 1058 and 1060, respectively, and opposed lower steps 1062 and1064, respectively. The heat sink is manually installed by orienting itslateral edges 1054 and 1056 within the opposed vertical slots 1036formed in the inserts 1006 and 1008, and lowering in into its installedposition. Refer FIG. 68. As the heat sink 1030 descends, the lower step1064 in the edge surface 1056 will initially slidingly engage aretention tab 1006 (refer FIG. 66) which is integrally formed withinsert 1008 and extends (in the relaxed condition) downwardly andlaterally inwardly, forming a downwardly facing catch or abutmentsurface 1068. As the heat sink 1030 further descends, the lower step1064 will momentarily displace the free end of the retention tab 1066laterally outwardly. Refer FIG. 67. As the heat sink 1030 approaches itsdesign intent installed position, the upper step 1061 will verticallyalign with the abutment surface 1068 of the retention tab 1066, whichwill snap back into its relaxed position, thereby positively locking theheat sink 1030 in the installed position. Refer FIG. 68. The heat sink1030 assumes its installed position when the lower step 1064 contacts abase surface 1070 of the insert 1008.

The PCB assembly 1018 and the CD player subassembly 1020 are installedlike drawers, and can be conveniently exchanged and repositioned withinthe confines of the sleeve 992, requiring only the replacement of thetrim panel 1028 to accommodate any new configuration.

Referring to FIG. 69, an alternative method of interconnecting a CDplayer subassembly inner sleeve 1072 with a left side insert 1074 and aPCB assembly 1076 within a housing sleeve 1078 of an alternativeautomotive audio system 1080 is illustrated. The only materialdifference of the embodiment of FIG. 69 contrasted with the embodimentof FIGS. 59-68, is the insert 1074 forms vertically spaced longitudinalslots 1082 and the inner sleeve 1072 forms cooperating laterallyoutwardly extending longitudinal guide bosses 1084 which are of adovetail configuration to laterally interlock the two.

Fold-Up Case

In this mechanical configuration, the case starts out as a flat set ofplastic sides with molded in metal mesh to act as the hinges for foldingthe case into a three-dimensional structure. This approach allows forbottom-up assembly that starts by snapping the board to molded featuresin the bottom plate. The heat sink is snapped to features in the backplate and the CD mechanism is attached to the front plate with twoscrews. The box is then folded up and snapped together.

The common edges of adjacent case panels define living hinges extendingpartially or entirely along the length thereof. The living hinge canconsist of wire mesh only, where there is a gap in the plastic material,as illustrated in FIG. 74. Alternatively, the living hinge can comprisea thin web of plastic only, wherein the wire mesh has been interrupted.In another embodiment, the plastic-wire mesh composite can be molded todefine a thin web as the living hinge, as illustrated in FIG. 71. Inanother embodiment, the plastic-wire mesh composite can be crushed ordeformed to define the living hinge, as illustrated in FIG. 76. Finally,a portion of the plastic and/or wire mesh can be scribed or machinedaway to expose the wire mesh to define the living hinge. If the casematerial is thin enough at the hinge point, the hinge can be segmented,rather than continuous.

Referring to FIGS. 70-77, several variants of a housing assembly 1086for an automotive audio system 1088 are illustrated. This version of theaudio system 1088 is configured to be hand assembled and is nearlyfastener-less. The fasteners which are employed are extremely elementaland require only the most rudimentary of hand tools to affect assembly.In essence, the audio system housing assembly 1086 comprises a caseportion 1090 and a closure member or front plate 1092. The case 1090 ispresented to the assembler in an unfolded, two-dimensional arrangementwhereby he/she can easily complete the final assembly process on a tabletop, eliminating complex and expensive tooling fixtures and multiplework stations.

The case portion 1090 is initially created as a sheet-like preform 1094consisting of a number of flat panels interconnected along theiradjacent edges. As best viewed in FIG. 70, the preform 1094 defines fivedistinct panels, which will constitute a bottom or lower wall portion1096, a right side wall portion 1098, a left side wall portion 1100, atop or upper wall portion 1102 and a rear wall portion 1104. Theadjacent panels are commonly joined or integrally interconnected byliving hinges 1106, enabling the panels to be repositioned normally toone another to form a three-dimensional box-like case 1090.

The preform 1094 can be die cut from a continuous sheet of sourcematerial or, alternatively, injection molded in a net shape asillustrated in FIG. 70. In either case, the material employed to makethe preform is a composite of at least one layer of relatively rigidpolymer based material and at least one layer of electrically conductivematerial capable of shielding audio components, such as a radio receivercircuit 1108 or a CD player subassembly 1110 from electrical anomaliessuch as radio frequency interference (RFI), electromagnetic interference(EMI), bulk current injection (BCI), and electrostatic discharge (ESD).Cooperating engagement features such as tabs 1112 and catches 1114 areaffixed to or integrally formed with the preform 1094. Refer FIGS. 72and 73. By way of example, after installation of the internalsubcomponents, the case preform is folded to assume its ultimatebox-like configuration. This places cooperating associated pairs of tabs1112 and catches 1114 in an assembly orientation with the tab 1112carried on the edge of one panel (the right side wall portion 1098, forexample) and the catch 1114 carried adjacent the edge of a now adjoiningpanel (the rear wall portion 1104, for example). Final structuralfixation of the preform 1094 in the form of the housing case 1086 iscompleted by simply snap-engaging the tab 1112 with the catch 1114 fromthe configuration of FIG. 72 to the configuration of FIG. 73. After allof the tab 1112/catch 1114 pairs are interconnected, the formation ofthe case 1090 is complete.

Prior to folding up the case 1090, the radio receiver circuit 1108 ispositioned and affixed to the exposed surface of the lower wall portion1096. A heat sink 1116 is similarly positioned and affixed to theexposed surface of the rear wall portion 1104. The positioning andattachment of the internal components can be accomplished by featuresintegrally formed in the formation of the preform 1094 (such as snaps,locating guides and the like), adhesives, discrete attachment and guideelements or inter-engagement with the various wall portions and otherassembly elements within the case 1090.

After formation of the case 1090, the CD player subassembly 1110 can bepre-assembled with the closure member 1092 via screws 1118 or otherinterconnecting features described herein. A rear bracket 1124 securedto the back side of the CD player subassembly 1110 by screws 1122includes a rearwardly extending threaded post 1124 which, upon finalassembly extends through registering passageways 1126 in the heat sink1116 and rear wall portion 1104 and engages a mounting bushing 1128.This arrangement provides an extremely robust overall structure to theoverall audio system.

The electrical components comprising the radio receiver circuit 1108 arearranged on a “common” component PCB 1130 and a “unique” PCB 1132. Thecommon and unique PCBs 1130 and 1132 are electrically interconnected bya ribbon connector 1134. The heat generating electrical components 1136are arranged on the common PCB 1130 and are affixed to the heat sink1116 by screws 1138 or other suitable means, to enhance thermal couplingtherebetween. Electrical connectors 1140 and 1142 are also arranged onthe common PCB 1132 in register with port openings 1144 and 1146 in therear wall portion 1104 of the case 1090. A vertically opening electricalsocket 1148 is centrally disposed in the unique PCB 1132 to receive arigid connector 1150 extending downwardly from the CD player subassembly1110. This arrangement electrically interconnects the two audiocomponents as well as provides structural support thereof.

One embodiment of the composite material employed for the housingassembly 1086 consists of a layer of elastomeric material 1152 with acontinuous wire screen 1154 insert molder therein adjacent an interiorwall surface 1156 of the composite structure. Referring to FIG. 71, theliving hinges can be formed by an extremely locally thin (ornon-existant) layer 1158 of polymeric material and the wire screen 1156.

Referring to FIG. 74, air vents 1160 can be provided in the case 1090 bylocally eliminating the polymeric material layer 1152 while maintainingthe continuity of the wire screen 1156 to permit airflow, as indicatedby arrows 1162, therethrough.

Referring to FIG. 76, an alternative living hinge 1164 can be formedpost-production of the composite material by pressing alternatingundulations 1166 therein along the axis of the intended living hinge1164.

Referring to FIG. 75, a first process for producing composite materialis illustrated, including drawing polymeric sheet material off upper andlower continuous rolls 1168 and 1180 to enclose an intermediate layer ofwire screen from a third roll 1172. The three discrete sheets are heatedat station 1174, rolled together at station 1176, cured at station 1178,cut-off or die cut to form performs at station 1180, scribed, punchedtreated and/or formed at a station 1182, and, finally, assembled at aworkstation 1184.

Referring to FIG. 75, a second, alternative process for producingcomposite material is illustrated drawing a continuous sheet of wirescreen off a roll 1186 and drawing it through a continuousextruder/molder 1188 to form the composite structure. Thereafter, thecomposite sheet is shaped at station 1190, cut off and/or punched at astation 1192, and, finally, assembled at a work station 1194.

Assembly of the audio system 1088 is completed by affixation of a trimplate subassembly (not illustrated) such as the device described inconnection with FIGS. 2-10 hereinabove.

I-Beam

In this mechanical configuration, the case starts out as a “I-beam”allowing the CD mechanism to be attached (bottom-up) to the top of theI-beam for high slot designs then the unit can be flipped over and theboard installed (bottom-up) on the bottom of the I-beam. The rectangularsolid nature of the I-beam allows it to sit squarely on a table top nomatter what the orientation eliminating the need for expensive fixturesat each work station.

Referring to FIGS. 78 and 79, an automotive audio system 1192 isconfigured to be hand assembled and is virtually fastener-less.Furthermore, this embodiment provides a partition structure providingupper and lower (reversible) assembly surfaces with integral closuremembers. The audio system 1192 comprises a simple sheet metal housingsleeve 1194 defining left and right side walls 1196 and 1198,respectively, a bottom 1200, a top 1202, and front and rear openings1204 and 1206, respectfully. An H-shaped (when viewed from the side)partition member 1208 is configured and dimensioned to establish aslip-fit within the sleeve 1194. The partition member 1208 isconstructed of upper and lower U-shaped sheet metal channel portions1210 and 1212, respectively. The upper channel portion 1210 comprises ahorizontal base portion 1214, a laterally extending vertically upwardlydirected front panel 1216 and a laterally extending vertically upwardlydirected rear panel 1218. The lower channel portion 1212 comprises ahorizontal base portion 1220, a laterally extending verticallydownwardly directed front panel 1222 and a laterally extendingvertically downwardly directed rear panel 1224. When the partition 1208is in the installed position illustrated in FIG. 79, the two frontpanels 1216 and 1222 are substantially co-planer and close the frontsleeve opening 1204. Likewise, when the partition 1208 is in theinstalled position, the two rear panels 1218 and 1224 are substantiallyco-planer and close the rear sleeve opening 1206. Accordingly, thesleeve 1194 and the partition member co-act to define a substantiallyclosed housing assembly 1226, which is subdivided into upper and lowerchambers or cavities. A trim plate subassembly 1228 snap engages thesleeve 1194 to complete the assembly of the audio system 1192.

In addition to serving as a closure member, the partition member 1208 isconfigured to facilitate the installation of audio system subcomponentssuch as a radio receiver circuit subassembly 1234 (illustrated inphantom) and a CD player subassembly 1236 (illustrated in phantom).Prior to its insertion into the sleeve 1194, the partition member 1208serves as a reversible assembly fixture that can be conveniently appliedon a flat work surface, without dedicated, expensive hard fixtures andtools. For example, with the partition member 1208 disposed in theillustrated, upright position, the radio receiver circuit subassembly1234 can be manually installed on the horizontal base portion 1214and/or the inner surfaces of the vertical panels 1216 and 1218 fromabove via self-positioning, self-engaging attachment features (notillustrated) of the types described elsewhere herein. Thereafter, thepartition member 1208 can be inverted and the CD player subassembly 1236can be manually installed on the horizontal base portion 1220 and/or theinner surfaces of the vertical panels 1222 and 1224 from above viaself-positioning, self-engaging attachment features (not illustrated) ofthe types described elsewhere herein. Note that, in this scenario, theCD player subassembly would be installed from above, but in the invertedposition.

The vertical height (H2) of the panels 1222 and 1224 of the lowerU-channel portion 1212 are dimensioned approximately 150% greater thanthe vertical height (H1) of the panels 1216 and 1218 of the upperU-channel portion 1210. This relationship permits the audio system 1192to be easily reconfigured between a top-mount CD player or abottom-mount CD player (by way of example only) either in the factory orin the field, merely with the replacement of the trim panel subassembly1228.

The U-channel portions 1210 and 1212 can be formed as a single integralunit, can be fabricated separately and subsequently joined such as bywelding, or can be pre assembled with their respective audio componentsubassemblies and separately installed within the sleeve 1194. Certaindetails, such as the heat sink, electrical connectors, and the like havebeen deleted here to avoid redundancy. It is contemplated that suchfeatures, as described elsewhere herein, can be applied in the presentembodiment.

Interlocking Block/Clam-Shell

In this mechanical configuration, the bottom of the case is plastic andcontains slots for the assembly of the boards. The sides of the casebottom provide a shelf for the CD mechanism to sit on. The back of thecase contains a vertical slot for a guillotine heat sink to beinstalled. The top of the box, also plastic, then slides over the CDmechanism and heat sink and snaps to the bottom trapping all of thecomponents in place. A plastic molded leaf spring in the back of the topwould apply a controlled down force on the heat sink for good thermaltransfer from the power devices.

Referring to FIGS. 80-82, an automotive audio system 1238 is configuredto be hand assembled and is virtually fastener-less. Furthermore, thisembodiment provides a “clam shell” type case assembly wherein one of thecase halves can be employed as an assembly fixture. The audio system1238 comprises a housing assembly 1240 including upper and lower casehalves 1242 and 1244, respectively. With the exception of specificsdescribed hereinbelow, the case halves 1242 and 1244 are substantiallysymmetrical. The upper case half 1242 is shaped generally as an inverted“U”, including a top wall portion 1246 and left and right downwardlyextending integral half-walls 1248 and 1250. The lower case half 1244 isshaped generally as a “U”, including a bottom wall portion 1252 and leftand right upwardly extending half-walls 1254 and 1256. Collectively, thecase halves 1242 and 1244 form front and rear openings 1257 and 1259. Atrim plate subassembly 1258 serves as a front case closure member and a“guillotine type” heat sink 1260 serves as a back closure member.

The upper case half 1242 has a number of integrally formed downwardlydirected snap tabs 1262 extending from the half-walls 1248 and 1250thereof which are configured to self-locate and self-engage a likenumber of mating snap receiving recesses 1264 integrally formed in thehalf-walls 1254 and 1256 of the lower case half 1244. Similarly, thehalf-walls 1248, 1250, 1254 and 1256 each have an integral forwardlyextending snap tab 1266 which self-locates and self-engagescorresponding snap receiving recesses 1268 integrally formed in left andright integral mounting flanges 1270 (only the right flange isillustrated) in the trim plate subassembly 1258 for the retentionthereof with the audio system 1238.

The half walls 1254 and 1256 of the lower case half 1244 integrally formlower longitudinally extending guideways in the form of opposed,laterally facing slots 1272 and 1274 for slidably receiving the PCB of aradio receiver circuit subassembly 1272 and upper longitudinallyextending guideways in the form of opposed stepped guide surfaces 1278and 1280 for slidably guiding the bottom surface of a CD playersubassembly 1282. Resilient localized spring fingers 1284 arecantilevered from the half-walls 1254 and 1256 to continuously bias theCD player subassembly 1282 upwardly against an upper stop 1286integrally formed in the upper case half 1230 to prevent vibration andrattles. The snap tabs 1262 extend laterally inwardly sufficiently tolaterally embrace the CD player subassembly 1282.

The lower case half 1244 has a longitudinally spaced pair ofcross-support members 1288 and 1290 integrally formed therewith definingand framing a vertically extending slot 1292 therebetween. Likewise, theupper case half 1242 has a substantially mirror image longitudinallyspaced pair of cross-support members 1294 and 1296 integrally formedtherewith defining and framing a vertically extending slot 1298therebetween. The cross-support members 1288 and 1290 provide lateralsupport for the upper rear portion of the lower case half 1244, and thecross-support members 1294 and 1296 provide lateral support for thelower rear portion of the upper case half 1242. The slots 1292 and 1298longitudinally coincide for receiving the heat sink 1260 therein. Afinger spring 1300 integrally formed in the top wall portion of uppercase half 1242 extends as a cantilever and continuously bears downwardlyagainst the upper surface of the heat sink 1260 to prevent vibration andrattles.

A major advantage of the present embodiment is that the lower case half1244 serves as an assembly fixture, which can be conveniently applied ona flat work surface, without dedicated, expensive hard fixtures andtools. Furthermore, all of the internal components can be manuallyinserted within the lower case half 1244 from above before the uppercase half 1242 is snap-fit into place completing the assembly process,with the sole exception of attaching the trim plate subassembly 1258.

“H” Shaped Case

In this mechanical configuration, the brackets traditionally placed oneach end of the CD mechanism become the left and right side of theradio. These end brackets provide slots in the bottom for the boards tobe assembled and a slot in the back for a guillotine heat sink. Thebottom and top of the case are then snapped into place to complete theassembly.

Referring to FIGS. 83 and 84, an automotive audio system 1302 isconfigured to be hand assembled and is virtually fastener-less.Furthermore, this embodiment employs a portion of the structure of anaudio component subassembly, such as a CD player subassembly 1304, to beincorporated within a housing assembly 1306 of the audio system 1302 toform a portion of the outer walls of the housing assembly 1306.

The CD player subassembly 1304 includes a generally rectangularself-contained enclosure including top and bottom panels 1308 and 1310,respectively, left and right side panels 1312 and 1314, respectively, afront panel 1316 and a rear panel (not illustrated). The side panels1312 and 1314 are extended vertically above the top panel 1308 and belowthe bottom panel 1310. Furthermore, the side panels 1312 and 1314 areextended longitudinally forward or the front panel 1316 and rearward ofthe rear panel. Thus constituted, the CD player subassembly 1304, whenviewed by itself from the front or rear, is configured to approximate an“H”. The side panels 1312 and 1314 can be integral extensions oftraditional configuration side panels formed at the time of manufactureof the CD player subassembly 1304 as an off-line process, or can beformed as discrete elements and affixed to a conventionally configuresCD player during final assembly of the audio system.

The housing assembly 1306 includes an upper closure member 1318configured as an inverted “U” defining a top portion 1320 and downwardlydirected, longitudinally extending left and right skirt portions 1322and 1324, respectively. The housing 1306 includes a bottom closuremember 1326 configured as a “U” defining a bottom portion 1328 andupwardly directed, longitudinally extending left and right skirtportions 1330 and 1332, respectively. The side panels 1312 and 1314combine with the upper and lower closure members 1318 and 1326 to form abox-like case 1334 defining a front opening 1336 and a rear opening1338. During final assembly of the audio system 1302, the front opening1336 is closed by a trim plate subassembly 1340 and the rear opening1338 is closed by a “guillotine type” heat sink 1342. The side panels1312 and 1314, respectively, the upper and lower closure members 1318and 1320, respectively, and the trim plate subassembly 1340 areinterconnected during final assembly by cooperating self-locating,self-guiding and self-engaging features integrally formed therein, suchas, by way of example, snap-lock features, as described elsewhereherein.

A first or upper cavity 1344 is formed within the case 1334 extendingvertically between the top panel 1308 of the CD player subassembly 1304and the top portion 1320 of the upper closure member 1318. Similarly, asecond or lower cavity 1346 is formed within the case 1334 extendingvertically between the bottom panel 1310 of the CD player subassembly1304 and the bottom portion 1328 of the bottom closure member 1326. Inthe presently illustrated embodiment of the audio system 1302, the uppercavity 1344 is employed for routing of electrical cables and convectioncooling air flow. The lower cavity 1346 is employed to enclose a secondaudio subassembly, such as a radio receiver circuit subassembly 1348.The portion of the inner surfaces of the side panels 1312 and 1314within the lower cavity 1346 have opposed, cooperating guideways 1350and 1352 formed thereon for slidingly receiving and supporting side edgesurfaces 1354 and 1356 of a unique PCB portion 1358 of the radioreceiver circuit subassembly 1348. A common PCB portion 1360 of theradio receiver circuit subassembly 1348 is supported by a second, lowerset of guideways (not illustrated). The common PCB portion 1360 carrieselectrical connectors 1362, which are externally accessible through aport opening 1366 in the heat sink 1342, and electrical power devices1364, which are thermally coupled to engagement surfaces 1368 of theheat sink.

A significant advantage of the present embodiment is that material (andweight) employed for the CD player subassembly closure panels and theaudio system case 1334 are conserved by the “compound structure” orhybrid configuration described. Furthermore, the CD player subassembly1304 serves as an assembly fixture, which can be conveniently applied ona flat work surface in both upright and inverted positions, withoutdedicated, expensive hard fixtures and tools.

Certain details, such as the snap-acting connector features, heat sinkdetails electrical connectors, and convection cooling passages have beendeleted here to avoid redundancy. It is contemplated that such features,as described elsewhere herein, can be applied in the present embodiment.

Laser Labeling of Plastic Case

Since the material for the receiver case will preferably be black or arelatively dark colored plastic, the paper label that is normallyapplied prior to shipment to identify the model of the radio and themanufacturer and customer part numbers can be eliminated and theinformation can be laser ablated onto the surface of the plastic at thesoftware programming station at the end of the production line. Thisimprovement not only eliminates the label (and one or more additionalpart numbers), but also adhesive and/or pre-application backing materialwhich must be removed prior to label application. Furthermore, suchautomated labeling directly on an outwardly visible surface of the radiocase, virtually ensures against production errors such as non-labeling(producing radios without any label), mislabeling (producing radios witha label bearing incorrect information) and misplaced labeling (properlabel incorrectly located so as to render it non-machine readable).

Filler material of a contrasting color can also be added during the casemolding process to render the laser produced label more easily readable.Such filler material can constitute a distinct inner layer extendingthroughout the entire part as molded, or can be applied only to alocalized region of interest on the molded part.

Referring to FIGS. 85 and 86, the physical assembly the automotiveradio/CD player 62 described hereinabove in connection with FIGS. 2-10is essentially complete when the trim plate subassembly 74 is affixed tothe closure member 70 which, in turn, has been previously affixed to thehousing case 68. For purposes of example, a region 1370 designated by anoutline 1372 is reserved on the right side wall portion 84 of the case68 for the application of permanent product and customer relatedinformation in both human and machine readable forms. The information istypically in textual/numerical form 1374 and in bar code form 1376.

The laser labeling or ablating is affected in accordance with thefollowing process. The process is initiated at step 1378, eithermanually or automatically. The process then flows to a step 1380 ofconfirming the presence of a production unit 62 at a softwareprogramming station on or adjunct to the production line. The processthen flows to a step 1382 of performing final programming andcalibration of the production unit 62. The process then flows to a step1384 of performing an operation functionality test. Next, the processflows to a step 1386 of assigning unit specific data to that specificproduction unit 62. Next, the process flows to a step 1388 of lasercalibrating unit specific and generic data in textual and/or bar codeform, 1374 and 1376, respectively, within the outline 1372 in thedesignated region 1370 on the external surface of the case 68. Next, theprocess flows to a step 1390 of recording the data in a memory device.Finally, the process flows to a step 1392 of ending the program andawaiting the next in line production unit.

Hybrid Case

FIGS. 97-119 describe several variants of hybrid case structures forradio/CD players adapted for automotive applications. A hybrid case isconstructed of different materials with disparate properties, such asmolded plastic portions in assembly with structurally supportive(stamped) metal frame elements. All or portions of the plastic case,including the faceplate, may have wire mesh insert molded therein toshield against electrical anomalies. The metal frame elements primarilyserve to structurally reinforce the plastic portions and can also defineinternal component and sub-assembly positioning/mounting features.Typically, one or more localized regions of embedded wire screen areexposed, either during the molding/formation process, or thereafter,employing secondary operations. In assembly, the exposed regions are incontact with the metal frame elements to ensure continuity of theshielding effect. The hybrid cases illustrated if FIGS. 97-119 aremodified I-beam (refer FIGS. 78 and 79) and interlockingblock/clam-shell (refer FIGS. 80-82). The embodiment of the automotiveaudio system described in connection with FIGS. 83 and 84 elsewhereherein is deemed to be of hybrid construction.

The hybrid case typically includes top and bottom plastic covers ofpolymer based material (preferably with molded-in wire mesh) and aone-piece multi-fold sheet metal part or chassis to up-integrate all thesheet metal parts together to reduce the screw fasteners, if not toentirely eliminate them. This structure can also be employed in radioarchitectures employing one-piece PCBs.

Referring to FIGS. 97-104 and 112-114, a first hybrid variant of anautomotive radio/CD player assembly 1394 includes a one piece multi-foldsheet metal chassis 1396 which affixes a CD player subassembly 1398, aradio receiver circuit assembly 1400 and a heat sink 1402 within theradio/CD player assembly 1394. A ribbon or flex wire cable 1404electrically interconnects the radio receiver circuit assembly 1400 withthe CD player subassembly 1398. Upper and lower plastic/wire meshclosure members 1406 and 1408, respectively, in combination with thechassis 1396, defines a substantially closed housing assembly 1410. Atrim plate subassembly 1412 is affixed to the housing assembly 1410. Arear mounting stud 1414 is affixed to a rearwardly directed membercarried by the chassis 1396.

Referring to FIGS. 105-111, a second hybrid variant of an automotiveradio/CD player assembly 1416 includes a one piece multi-fold sheetmetal chassis 1418 which affixes a CD player subassembly 1420, a radioreceiver circuit assembly 1422 and a heat sink 1424 within the radio/CDplayer assembly 1416. A ribbon or flex wire cable 1431 electricallyinterconnects the radio receiver circuit assembly 1422 with the CDplayer subassembly 1420. Upper and lower plastic/wire mesh closuremembers 1426 and 1428, respectively, in combination with the chassis1418, defines a substantially closed housing assembly 1430. A trim platesubassembly 1432 is affixed to the housing assembly 1430. A rearmounting stud 1434 is affixed to a rearwardly directed member carried bythe chassis 1418.

Referring to FIGS. 115-118, a third hybrid variant of an automotiveradio/CD player assembly 1458 includes a one piece multi-fold sheetmetal chassis 1460 which affixes a CD player subassembly 1462, a radioreceiver circuit assembly 1464 and a heat sink 1466 within the radio/CDplayer assembly 462. A ribbon or flex wire cable 1468 electricallyinterconnects the radio receiver circuit assembly 1464 with the CDplayer subassembly 1462. Upper and lower plastic/wire mesh closuremembers 1470 and 1472, respectively, in combination with the chassis1460, defines a substantially closed housing assembly 1474. A trim platesubassembly 1476 is affixed to the housing assembly 1474. A rearmounting stud 1478 is affixed to a rearwardly directed member carried bythe chassis 1460.

Faceplate with Integral Lightpipe

Additional part count reduction and assembly simplicity can be achievedby integrally forming light pipes within the front plate of the radio/CDplayer employing a two-shot molding process. This eliminates orsubstantially reduces the number of light pipes and fasteners. ReferFIG. 120. Overall quality is also improved by the elimination of thepossibility of misassembled and loose or misplaced parts.

The integrally molded light pipes facilitate the subterranean lightingmethod currently used with side firing surface mount LEDs (5 total) thatare attached to the back of the keyboard. Typically, a blue LEDdistributed light through a clear polycarbonate light pipe and passesthe light through the pushbutton which is painted and laser etched forthe nighttime viewability of the graphics on the pushbuttons of theradio. The LEDs are preferably mounted on the back of the keyboard. Theforward facing extensions depending from the light pipes typicallyextend through registering holes (not illustrated) in the keyboard tospecifically illuminate a particular button or device on the keyboard.

The preferred material for the light pipe is polycarbonate as well asthe front plate. White polycarbonate would be used for the front platewith an opacifier (to stop light bleed) to enable the light to be moreefficient passing there through. Black material would draw light energyfrom the light pipe.

The present invention, now permissible because of the plastic frontplate, enables better assembly and better tolerance stack-up of parts.This would take four separate parts and combine them into one. It alsoopens up possibilities of using acrylic for the light pipe now there isno need for a fastener or snap (acrylic is more brittle thanpolycarbonate, but offers more preferred light characteristics fordifferent wavelengths of light over long runs).

The two-shot front plate with integral light pipes combines fourseparate parts that must be assembled into one multi-functional part.Typically, the light pipes must be assembled with relative accuratelocating features that are aligned to accommodate the minimized air gaprequired for an efficient light entry from the source leds used toilluminate the push buttons and halo rings of the trim plate assemblyfor the radio. Often, these parts are fastened with snaps or screws or acombination thereof to enable retention of the assembly under amultitude of environmental and driving conditions. Due to the relativebrittleness of the better light pipe materials, screws may be requiredfor the material of the light pipe may not be robust enough to survivethe stress of a snap. These characteristics often make light pipeassembly a tedious task for the assembler and the designer to providethe optimal light delivery without degradation from misalignment ordamage during the assembly process.

The two shot plastic process enables combining two different materialsinto a single piece part which in this case permits the best features ofboth materials to perform the functions needed to achieve a successfulcomponent. The light pipes can be the first shot to be ganged to beconsistently located in the most accurate locations needed for optimallight entry from the leds and light exit for the respective deliverypoints to the backlit areas of the trim plate assembly. The second shotwould enable the light blocking and the structural component to providethe snap retention features of the front plate as well as the normalfront plate functional items.

Often the concern with light pipes might be the close proximity of ablack material that may absorb the light energy that travels through thelight pipe. This is typically why there is an air gap between any blackmaterial component and any adjacent light pipe. To overcome thispotential degradation, the front plate can be molded with a whitematerial, even with an opacifier if needed. Another method would be tolimit the points of contact between the light pipe material and thestructural frame-like material component. This induces an air gap in theareas of illumination and still provides interface between the materialsto form a single part.

The two shot process typically has a first shot of material into a mold.Next the mold is rotated and the second shot of material is provided tocomplete the part. In this case, the first shot would be the light pipeportion, followed by the structural portion.

This inventive design will also offer greater flexibility for assemblingthe trim plate and case assembly as well.

Although this lighting approach is primarily intended for use on thefront plate, it could also be employed in the radio case itself if acontrolled light output in non traditional directions from the radioassembly is desired.

It is contemplated that screen mesh can be insert molded within thefront face simultaneously with the above described subterranean 2-shotlight pipe forming process. In this case, the screen mesh wouldpreferably be positioned inwardly of the light pipes within the frontplate structure. Alternatively, the screen and light pipe positions canbe reversed. However, this would be more complex and require that thelight pipe extensions pass through registering apertures in the screen.

Referring to FIG. 120, a known trim plate assembly 1480 is illustratedto highlight the substantial complexity, high part count, and designshortcomings resulting from providing back-illumination usingtraditional design and assembly techniques. The trim plate assembly 1480includes a black plastic front panel 1482 (with operator controls anddisplays affixed on the opposed side), a printed circuit board (PCB)1484 mounted on the exposed face of the front panel 1482, three separateand discrete lightpipes 1486 mounted on the exposed face of the PCB 1484by eight fastening screws 1488 and five light emitting diodes (LEDs)1490 carried on the PCB 1484.

Referring to FIG. 165, a generic two-shot injection molded article 1492is formed from a two-shot molding process wherein the first shot is ofclear acrylic and results in a buried light pipe portion 1494 and anextension portion 1496 directed toward the viewer (arrow) 1498. Thesecond shot is of white acrylic with an opacifier, simultaneouslyforming a mask and robust structural element 1500. The mask/structuralelement 1500 is integrally formed with the lightpipe portion 1494 andextension portion 1496. A pocket 1502 is formed in the mask/structuralelement 1500 for receiving an LED 1504 which is electricallyinterconnected with a PCB (not illustrated) via leads 1506.

The two shot process eliminates the necessity for using separatefasteners and permits use of optically preferable materials such asacrylics. There are no small parts to come loose or be misassembled.

Referring to FIGS. 121-126, the structural configurations of the firstshot polymeric material and the second shot polymeric material areillustrated separately and in combination. FIGS. 121 and 123 illustratea fully formed two-shot audio system housing assembly closure member1508. The closure member 1508 includes three lightpipes 1510, 1512 and1514 formed as first shots of clear acrylic material. After finalassembly with the trim panel subassembly and PCB, five LEDs 1516, 1518,1520, 1522 and 1524 will be arranged in respective pockets 1526, 1528,1530, 1532 and 1534 for illuminating the lightpipes 1510, 1512 and 1514.Multiple extensions 1536 extend outwardly (toward the trim plateassembly). The closure member further includes a mask/structural portion1538 formed as a second shot of white acrylic material, including anopacifier. A shaped opening 1540 is formed in the closure member 1508 toprovide access to a CD player subassembly behind the closure member1508.

Referring to FIG. 122, the reverse side of closure member 1508 revealsonly the second shot mask/structural portion 1538.

Referring to FIG. 124, a three dimensional envelope 1542 of themask/structural portion of the closure member formed by the second shotalone is illustrated as viewed from the front side.

Referring to FIG. 125, a three-dimensional envelope 1544 of the threelightpipes of the closure member formed by the first shot alone isillustrated as viewed from the front side.

Referring to FIG. 126, the three-dimensional envelope 1544 of the threelightpipes of the closure member formed by the first shot alone isillustrated as viewed from the back side.

Media Drawer for Automotive Audio System

With the 2DIN radio or audio system configuration, there exists enoughinternal volume within the housing assembly to configure the pushbuttonsand display layout to accommodate a front accessible area that canenable a platform or drawer to hold multiple devices such as an iPod™ orsimilar player, and also a flash memory stick. This platform or drawerwould then be pushed and seated within the radio to enable a securemechanical retention as well as making an electrical connection to allowthe devices to be powered and communicate with the audio system radio,even when the drawer is closed and secured.

The front of the platform or drawer matches the opening of the radiochassis both aesthetically and structurally, and be of a style thatcould be detached and applied to an updated or alternative platform ordrawer, should the desired devices change or evolve during the lifetimeof the host vehicle. The electrical and mechanical interconnects arelargely standardized and, thus, would be the same, enabling the consumerto change the platform or drawer at any time depending upon his/herpersonal requirements.

Presently, detachable faceplates for single DIN radios exist that haveboth the electrical connection and mechanical retention that could beused in this format. However single DIN radios are not large enough toaccommodate multiple audio subassemblies such as a radio receivercircuit subassembly and a CD player subassembly while reserving enoughcontiguous internal volume to accommodate a flush-mount media drawer.

The present invention allows the existing radio to be updated ormodified according to the wants and desires of the customer regardingthe preferred music device without having to remove the radio from theinstrument panel or impacting the normal production run of the radio.The size of the platform or drawer would be a standard as well as theelectrical and mechanical interfaces to enable continuous offerings asdealer and after-market stock for customizing the radio.

The nature of the component having electrical connection capabilityenables incorporation of other desired features like “Bluetooth”™connectivity as yet another option that could be incorporated into theplatform or drawer.

With front panel accessability, there would be the capability for theradio manufacturer to provide reflash programming capability withminimal service impact (like having to remove the radio from theinstrument panel), by using the electrical interconnect and to theaccess provided to the radio by the present invention.

The present invention eliminates the need for costly harness attachmentthrough the glove box. It would maintain the device location within theconfines of the audio system/radio housing to prevent contamination ordamage and eliminate any issue with vehicle occupant impact during abraking event or crash. Furthermore, when installed within the drawer,the device is relatively secreted from view from outside the hostvehicle, and is thus less likely to attract unwanted attention from aprospective miscreant. With the connection flexibility due to theinterchangeable platform or drawer, virtually any known device can beaccommodated to permit direct control through the radio, enhancingdriver/passenger convenience and safety as opposed to trying to controla separate device away from the immediate driver view.

FIG. 127 illustrates known approaches for configuring ports within anautomobile 1546 for interfacing a personal portable digital device(PPDD) 1548 with the an audio system 1550 embedded within the vehicle'sinstrument panel 1551 to access the vehicle's electrical network. Mosttypically, such capability is employed for playing pre-recorded musicfiles stored in the PPDD 1548 through the vehicle's speaker system.Ports or auxiliary jacks 1552 most often are incorporated in the exposedfront face or control panel 1556 of the vehicle's radio. Interconnectionof the PPDD 1548 is affected by an umbilical cable 1558 extendingtherebetween. Unfortunately, the PPDD 1548 is frequently placed in areassuch as a vehicle cup holder, ash tray, arm rest or the like notdesigned for securing such articles. In addition to being aestheticallyundesirable, this can expose the PPDD to damage or theft, and can bedistracting to the driver. Furthermore foreign articles placed invehicle passenger cabins can pose an impact risk or entanglement betweenthe umbilical cable 1558 and vehicle occupants, controls or otherelectrical/electronic devices (e.x. cell phones, laptop computers,portable DVDs, television monitors, power/recharging cables, and thelike). A partial solution has been proposed of locating the port orauxiliary jack 1552′ within the vehicle's glove box. However, this canexacerbate the distraction issue by locating the PPDD 1548′ further fromthe driver's field of vision. Furthermore, it can result in the vehiclebeing operated for sustained periods with the glove box door remainingin the open position. Lastly, PPDDs located in the glove box are subjectto damage or inadvertent resetting of their controls by impacting otherobjects in the glove box. In both traditional locations, the PPDD is nottypically secured and is prone to falling or damage.

Referring to FIGS. 128-132, 166A and 166B, an exemplary embodiment ofthis aspect of the invention is illustrated. A large format audio system1562 includes a plastic/wire screen composite case 1564 and aplastic/wire screen composite closure member/front plate 1566 whichcombine to form a housing assembly 1568. A front trim plate 1570 ismounted to the closure member 1566 for installation in a host vehiclepassenger compartment or instrument panel for access by an operator orpassenger to the controls and displays arranged about the outer visiblesurface 1571 thereof. A laterally elongated rectangular opening 1572 inthe lower portion of the front trim panel subassembly 1570 providesaccess to a cavity 1574 within the housing assembly 1568. A media drawer1576 is configured and dimensioned to be longitudinally inserted intosaid cavity 1574 through the trim panel opening 1570 and, inapplication, is manually operable for displacement between a “closed”position illustrated in FIG. 130 and an “open” position illustrated inFIGS. 129 and 129.

The media drawer 1576 is configured to approximate a relatively shallow,open-top box including a vertical front panel 1578, a bottom panel orplatform 1580, parallel left and right vertical side panels 1582 and1584, respectively, and a vertical rear panel 1586. The panels 1578,1580, 1582, 1584 and 1586 are integrally formed from injection moldedpolymer material or, preferably, a polymer/wire screen composite.Laterally outwardly projecting, longitudinally extending bosses 1588 areintegrally formed on the outer walls of the left and right side walls1582 and 1584 to define drawer guide surfaces which mate withcooperating guideways 1590 formed on the inner surfaces of the audiosystem case sidewalls 1592, or other suitable internal housing assemblystructure. When the media drawer 1576 is closed, a front surface or face1594 of the front panel is substantially flush with the front face 1571of the front trim panel 1570.

The faces 1571 and 1595 are aesthetically stylized to mask or obfuscatethe presence of drawer 1576. Unobtrusive instructional indicia 1596 maybe added on the front drawer surface 1594 as an aid for the user. Thebosses 1588 and cooperating guideways also include integral features(not illustrated) to establish longitudinal stops, preventing the mediadrawer 1576 from inward longitudinal displacement beyond the positionillustrated in FIG. 130 and outward longitudinal displacement beyond theposition illustrated in FIGS. 128 and 129.

Referring to FIGS. 129 and 130, the audio system 1562 includes audiocomponents such as a radio receiver circuit assembly 1598 and a CDplayer subassembly 1600 mounted within the housing assembly 1568. Asdescribed in greater detail elsewhere herein, the radio receiver circuitassembly 1598 has its circuit components mounted on a unique PCB 1602 ora common PCB 1604. A flexible, elongated cable 1606 is connected to thecommon PCB via a plug 1608 at one end and to the rear panel 1586 via aport 1610. The cable 1606 is routed above and behind the media drawer1576, entirely within the housing assembly 1568, so as to be hidden fromthe operator, and is long enough to maintain continuity between thecommon PCB and the port 1610, independent of the position of the mediadrawer 1576.

The cable 1606 can provide an electrical ground path between the wirescreen embedded within the media drawer to the wire screen embeddedwithin the housing assembly case 1564 and closure member 1566.Alternatively, exposed adjacent wire screen portions in the media drawer1576 and case 1564 can provide a direct, continuous ground path.

Referring to FIGS. 166A and 166B, additional convenience can be providedin the operation of the media drawer 1576, by providing a “push-push”type latching and unlatching mechanism 1612, which is known in otherunrelated applications such as push-button electrical switches. Forexample, refer U.S. Pat. No. 5,727,675, the specification of which isincorporated herein by reference. In essence, the push-push mechanism1612 selectively interconnects the media drawer 1576 and the housingassembly 1568 and provides a slight “lost motion” to the media drawer1576 longitudinally inwardly of the position depicted in FIG. 130. Asillustrated in FIG. 130, the media drawer 1576 is latched in the closedposition, whereby vehicle operation will not result in unintendedopening. Whenever an operator desires to gain access to the mediadrawer, he/she need merely momentarily push the drawer slightlylongitudinally inwardly. The inward movement of the drawer will releasethe latch 1614 and a compression spring 1616 will displace the drawer1576 to the position illustrated in FIGS. 128 and 129. Conversely.Whenever an operator desires to close the media drawer 1576, he/she needmerely again push the drawer 1576 longitudinally inwardly to a positionslightly inwardly of that illustrated in FIG. 130 and thereafter releasethe drawer 1576. This motion will cause the latch 1614 to self engageand the drawer will again be fixed in the closed position of FIG. 130.Alternatively, a handle or finger catch (not illustrated) can beemployed.

The media drawer 1576 is dimensioned and configured for flexibility forreceiving all known (current and future) PPDDs. However, as newtechnologies emerge, it is envisioned that the drawer 1576 can be easilyexchanged for a newly configured design without modifying the host audiosystem 1562 and vehicle. As described herein, many current PPDDs can beinterfaced with a host vehicle audio system simply by opening the mediadrawer, plugging a PPDD 1618 into the port 1610 via a PPDD suppliedinterface cable 1620, placing the PPDD 1618 and its cable 1620 into thedrawer 1576 and closing the drawer 1576.

Referring to FIG. 131, an alternative media drawer 1642 is illustrated.The media drawer 1642 includes integrally formed front panel 1644, abottom panel 1648, side panels 1650 and a rear panel 1652 similar tothose of media drawer 1576 described hereinabove. In some applications,an application specific interface electronic device 1654 may be requiredto establish compatibility between a PPDD 1656 and the host audiosystem. The electronic device 1654 can be built into the media drawer1642 and interconnected to the PPDD via a cable 1658 as well as the hostaudio system as described elsewhere herein. Multiple, supplemental nondedicated ports 1655 and 1657 can also be provided within the mediadrawer 1642.

Referring to FIG. 132, a second alternative media drawer 1660 is viewedfrom the rear, and includes a front panel 1662 and a bottom panel 1664.The front panel 1662 has interface wiring embedded therein and providesmultiple ports, such as a “memory stick” port 1666, a large formatconnector (such as USB type) 1668 for attaching large, out-sizeperipheral devices, as well as a port (not illustrated) for connectingwith a PPDD 1670. Hold-down features, such as integrally formedresilient self-latching tabs depend from the platform/bottom panel 1664.Laterally outwardly directed, longitudinally extending guide bosses 1674can be integrally formed in the bottom panel 1664.

Squirts

To further the innovative construction of the present invention,“squirts” or screwless retention features are employed. Restated,squirts are a drawn feature from a structural element, or a styledprotrusion at the interface of two structural elements. Althoughapplicable broadly, squirts are principally applied in the preferredembodiment of the invention to secure the CD player subassembly to theleft and right CD player guide brackets. This allows the elimination ofsix additional screws.

A squirt is a retention feature which is integrally formed in atypically planer region of a structural member, such as a CD playerguide bracket, which extends above one surface thereof and, duringassembly, self-engages within an opening formed in an adjacentstructural element, such as a hole in the outer case of the CD playersubassembly. Squirts permit assembly of the guide brackets to the CDplayer assembly by hand without the need for special fixtures and powertools.

The squirts are formed from stock material during formation of thebrackets themselves and do not add significant cost to the finalizedbracket component. Similarly, mating holes can be easily punch formed inthe adjacent case panels of the CD player subassembly.

In addition to reduced cost and ease of assembly, the squirt self-alignsthe respective components during the attachment process, therebyensuring their precise juxtaposition. Furthermore, the squirt ispermissive of lower tolerances in the forming and assembly of itsassociated elements. In fact, the presence of slightly misshapenfeatures or metal flash resulting from low tolerance punching operationscan actually result in enhanced retention performance.

Referring to FIGS. 140-143, the application of “squirts” 1676 to affixthe left and right side mounting brackets, 106 and 108, respectively tothe multi-disc CD player unit 104 to form the CD player subassembly 66,is illustrated. The squirts are preferable die-punch formedsimultaneously with the formation of the mounting brackets 106/108themselves. It is noted that the brackets 106/108 can be configuredsymmetrically, whereby one design can be used for both sides of the CDplayer unit 104, thereby further reducing the overall part count. Thesquirts 1676 are preferably formed on relatively regions 1678 of theirassociated bracket 106/108. A single through passage 1680 if formed inthe planer region 1678. Two or more substantially symmetrical forms 1682extend radially inwardly from the edge of the through passage 1680. Eachform 1682 has a neck region 1684 and a tapered region or sector 1686.The tapered region 1686 is supported as a cantilever by the neck region1684. The tapered regions 1686 collectively co-act to define (in thecase of two forms) a bisected frustoconical form, wherein each taperedregion 1686 defines an outside peripheral surface 1688 which are acutelyconverging upon an axis normal to the planer region 1678. The taper ofan imaginary cone 1700 extended from surfaces 1688 is designated by theangle w. As illustrated by alternative phantom depictions, the overallshape of the imaginary cone 1700 can be parabolic or hyperbolic. Theouter peripheral surface 1688 of each tapered region or sector 1686 hasa circumferential range designated by the angle θ, which with two formsis preferably in the range of 90°-120°.

In application, the collective outer peripheral surface of the sectors1686 engage a surface forming the outer diameter of a recess or throughhole 1702 in an adjacent structure 104 to which the bracket 106/108 isto be attached. As illustrated in FIG. 141, the maximum diameter edgesurface 1704 sectors 1686 effect line contact to maximize pull-outperformance.

Referring to FIG. 143, localized radially outwardly projecting knurls,ridges or extensions 1706 to provide point contacts with the adjacentstructures.

Attachment of the squirt 1676 to an adjacent structures is affectedsimply by aligning the sector 1686 with the through hole 1702 andpressing inwardly, as indicated by the phantom finger tip and resultantforce arrow 1708.

Plug-In Satellite Communication Module

Satellite radio is enabled through three primary approaches in the OEMradio market. There is an auxiliary box that plugs in-line to the radio.There is a separate shielded and enclosed module that is attachedmechanically and electrically to the inside of the radio on the maincircuit board. They are typically enclosed by two die cast halves or asheet metal enclosure. There is also a component block of electricalparts that is soldered to the main circuit board inside the radio thatmay require a shield for electrical protection.

While these approaches enable satellite radio, the shortcomings are theymay require distinction of either XM or Sirius as the provider and withthe exception of the separate in-line auxiliary box, are not upgradableshould the provider change or hardware updates become available.

The present invention employs a plug-in module enabling the OEM radio tobe configured at either end of the assembly area to accommodate anysatellite radio provider or hardware upgrade. Because it is a directplug-in to the radio, there is less reliability concerns than thein-line auxiliary box and less real estate required in the vehicle. Withthe module plugging into the rear of the radio, the module can be easilychanged or upgraded at the vehicle dealer or an aftermarket retailer bysimply extracting the radio, disconnecting the existing module, andreplacing it with a new module. The module has the integrated in-moldedmesh in plastic technology described elsewhere herein to provide anyrequired shielding/grounding. The plastic allows for slide lock, snaplock assembly to the radio chassis. The electrical connection can bethrough a docking style connector or even a ziff format ribbon cable(similar to the CD mechanism). With internal attachment modules, thereis not the flexibility to interchange modules or upgrade withoutdisassembling the radio and desoldering the unit.

Another advantage of the plug-in module is the ease of assembly of themodule itself. The in-molded mesh in plastic approach allows for ascrewless assembly and provides less handling concerns over a die castor sheet metal enclosure. The cost should be substantially less than thedie cast and equal to or less than that of the sheet metal.

Referring to FIGS. 146-149, an automotive audio system 1710 includes ahousing assembly 1712 enclosing one or more audio system subassemblies,such as a radio receiver circuit assembly 1714. The housing assembly1712 includes a box-like housing case 1716 and a front closure member(not illustrated) which enclose the audio system subassemblies 1712. Thehousing case 1716 and the closure member are each preferably formed as acomposite including wire screen insert molded within a polymer basedmaterial. FIG. 147 illustrates a left side wall portion 1718, a rearwall portion 1720 and a bottom wall portion 1722 of the audio systemcase 1716. All of the constituent wall portions of the case 1716 arepreferably injection molded as a single part to simplify assembly,minimize part cost and to maximize the wire screen's effectiveness inshielding the audio components from electrical anomalies including RFI,EMI, BCI and ESD.

One of the wall portions (e.g. the rear wall portion 1720) has anopening 1724 formed therein for receiving a plug-in module 1726 foraffecting satellite radio reception capability for the otherwiseterrestrial radio receiver 1714 within the audio system 1710. The radioreceiver circuit assembly 1714 includes a PCB 1728 carrying a dockingtype connector 1730 aligned with the opening 1724 whereby an electricalplug (not illustrated) carried on the plug-in module 1726 engages thedocking connector 1730 upon insertion of the plug-in module 1726 withinthe opening 1724 as illustrated in FIGS. 146 and 147. Alternatively, anelongated, flexible ribbon-type connector can be affixed the radiocircuit PCB 1728 which, when a plug-in module 1726 is to be installed,is first manually drawn out of the case 1716 through the opening 1724,attached to the module electrical plug, and reinserted back through theopening 1724 in assembly with the module 1726.

The plug-in module 1726 includes a housing 1732 which is generallyrectangular in shape. The module housing 1732 has upper and lower wallportions, 1734 and 1736, respectively, left and right side wall portions(as viewed from the bask of the housing assembly 1712) 1738 and 1740,respectively, a front wall portion (facing outwardly) 1742 and a backwall portion 1744 (facing inwardly) 1744. The housing 1732 is preferablyformed as a composite including wire screen insert molded within apolymer based material and has a “clam-shell” type architecture. Thehousing can be assembled from two discrete elements, one including theupper wall portion 1734 integrally formed with top half-wall portions ofthe side walls 1738 and 1740, the front wall 1742 and the back wall1744, and the other including the lower wall portion 1736 integrallyformed with bottom half-wall portions of the side walls 1738 and 1740,the front wall 1742 and the back wall 1744. Each of the two discreteelements can include self-aligning, self-guiding and self-engagingfeatures integrally formed therewith. Alternatively, the two elementscan be molded as a single element with one set of opposed edgesinterconnected via an integral web or living-hinge. For example, referFIGS. 161-163. Upon assembly of the plug-in module 1726, the electricalplug is supported at and extends from the back wall portion 1744. Aconnector (co-axial) 1746 extends outwardly from the front wall portionwhich is adapted for interconnection with a host vehicle satelliteantenna system.

The wire screen contained within the plug-in module 1726 can be groundedto the wire screen contained within the audio system housing assembly1712 by either providing adjacent exposed portions of wire screen thatare configured to remain in intimate contact or, alternatively, they canbe grounded remotely via mating conductors in the associated radioconnector and module plug.

The plug-in module 1726 is retained in its installed position within theaudio system 1710 by two, opposed snap-acting retention arms 1748 and1750 integrally formed with the module housing 1732. Retention arm 1748includes a base portion 1752 integrally formed with the right sidewallportion 1740 of the module housing 1732 and extending laterallyoutwardly therefrom. The retention arm 1748 also includes an elongatedlever arm portion 1754 which is integrally formed with its associatedbase portion 1752 and extends longitudinally rearwardly therefrom as acantilever beyond both the exterior wall portion 1742 of the modulehousing 1732, and the housing case rear wall portion 1720. Therearwardmost end of the lever arm portion 1754 is exposed and defines afinger grip surface 1756. The lever arm portion 1754 forms a localizedlaterally outwardly directed upset 1758 therein forming a forwardlyfacing ramp surface 1759 and a rearwardly facing abutment surface 1760.When assembled, the rearwardly facing abutment surface 1760 on the leverarm 1754 longitudinally aligns with a forwardly facing abutment surface1762 formed in the case opening 1724.

The other retention arm 1750 is a minor-image of retention arm 1748 andfunctions as described hereinabove. Retention arm 1750 has acantileverlever arm portion 1764 which extends rearwardly beyond boththe exterior wall portion 1742 of the module housing 1732, and thehousing case rear wall portion 1720. The rearwardmost end of the leverarm portion 1764 is exposed and defines a finger grip surface 1766laterally opposite finger grip surface 1756 of lever arm portion 1754.

When the plug-in module is installed, guideways (not illustrated) withinthe audio system housing assembly 1712 adjacent the opening 1724cooperate with guide surfaces defined by outer surfaces of the modulehousing 1732 to affect self-location, self-guiding and self-engagementof the plug-in module 1726 within the audio system housing assembly1712. As the module enters into the opening 1724, the ramp surfaces 1759cause the lever arms 1754/1764 to be laterally displaced toward oneanother. Once the abutment surfaces 1760 and 1762 align, the naturalresiliency of the lever arms will result in their snapping back intotheir illustrated positions, thereby interlocking the module 1726 in itsdesign location. The module can be removed simply by simultaneouslygripping the two surfaces 1756 and 1766 and squeezing them together,thereby releasing the respective pairs of abutment surfaces 1760 and1762.

Although much of the forgoing description has been focused on automotiveaudio based entertainment systems, the explosive growth ofcommunications and navigation technologies have somewhat blurred theirtraditional distinctions. This issue is particularly acute in automotivesystems and personal portable digital devices. Referring to FIGS.161-163, as an example, a telematic device, i.e. a device employed forone or two way communications is illustrated. The telematic device 1768,when packaged for automotive application, employs design methodologieswhich overlap into traditional, purely passive automotive entertainmentsystems. The telematic device 1768 of the present invention includes aone-piece housing 1770 molded as a composite of polymeric material witha wire screen insert such as described elsewhere herein in the contextof other applications.

Referring to FIGS. 167-169, the “slide-lock” and “snap-lock” aspect ofthe inventive features described elsewhere herein is also applied toassembly of a closure member or front plate 1772 with trim platesubassembly 1774 including a display/control panel PCB 1776, a trimplate bezel 1778 and a trim plate facia 1780. The front plate 1772 isinjection molded of relatively rigid polymer based material, andincludes features integrally formed therewith for affectingfastener-less interconnection with the housing case (not illustrated) ofa lightweight automotive audio system 1782. Although the closure member1772 is depicted as being formed entirely of polymer based material, itis contemplated that it could have a composite structure of polymer andelectrically conductive material such as wire screen. Furthermore, theclosure member could also be injection molded of optically optimizedmaterial such as acrylic in a two-shot process for integrating lightpipes therein to provide back illumination of trim plate controls anddisplays. In this case, the light pipes would include a number ofintegral, longitudinally outwardly directed extensions passing throughregistering apertures in the display/control panel PCB 1776 (notillustrated).

Preferably, the closure member 1772 includes several split snap-catches1782 extending forwardly from the closure member front surface 1786. Thesnap-catches 1784 extend through registering apertures 1788 in thedisplay/control panel PCB 1776. Each of the snap-catches 1784 alsoinclude an integral standoff 1790 which functions to space the PCB fromthe closure member front surface 1786 to provide component clearance andenhance cooling. The closure member 1772 includes a number of outwardlyextending ramped tabs 1792 distributed about the exposed periphery 1794thereof.

The trim plate bezel 1778 is constructed of substantially opaque moldedpolymer material suitable for decorative finishing by painting or adeposition process. The bezel 1778 has openings/through holes (notillustrated) therein registering with an array of rear loaded actuatordevices and displays carried on the display/control panel PCB 1776, andassociated front loaded pushbuttons. The bezel 1778 also forms openingsor transparent/translucent windows for back lighting of the pushbuttons, displays and informational indicia (not illustrated). The bezel1778 has a peripherally extending step 1796 formed on the inside surface1798 thereof which abuts the outer surface 1800 of the PCB 1776 toensure precise spacing and registration between the controldevices/displays and their respective openings/through holes. Tabengaging extensions 1802 including abutment recesses 1804 are integrallyformed with the bezel step 1796 and extend rearwardly therefrom toengage corresponding ramped tabs 1792.

The bezel 1778 has a longitudinal riser defining a peripheral edge 1806extending between the step 1796 and the bezel front face 1810. The bezel1778 includes a number of circumferentially arranged outwardly extendingramped tabs 1810 integrally formed on the peripheral edge 1806 thereof.

The trim plate facia 1780 can be employed in certain applications tocomply with extremely high color and finish requirements and to avoidaesthetically objectionable distortions sometimes inherently resultingfrom the bezel 1778 injection molding process. The facia 1780 has a verythin section and is preferably injection molded of high quality polymerbased material suitable for decorative finishing or a depositionprocess. As best illustrated in FIGS. 168 and 169, the facia has anabbreviated peripheral side wall portion 1812 forming circumferentiallyarranged tab receiving recesses 1814 on the inside surface 1816 thereof.The facia 1780 has openings/through holes (not illustrated) thereinregistering with corresponding openings/through holes in the bezel 1778.The facia also has openings or transparent/translucent windows for backlighting of the push buttons, displays and informational indicia. Wheninstalled, the inside face 1818 of the facia is disposed in intimatecontact with the outside face 1820 of the bezel 1778.

FIG. 168 illustrates a bezel 1778 constructed of opaque material with a“first surface” finish layer 1822. FIG. 169 illustrated an alternativebezel 1780′including an inside face 1818′ and a side wall portion 1812′having an inside surface 1816′ forming a tab receiving recess 1814′. Thealternative bezel 1780′ is constructed of optically clear ormonochromatically tinted polymer based material with a “second surface”finish layer 1824.

Referring to FIG. 144, the outer surface 1826 of a closure member/frontplate 1828 for an automotive audio system includes three splitsnap-catches 1830 integrally formed thereon. In addition, two integrallocator pins 1832, including standoffs 1833 cooperate with the splitsnap-catches 1830 to self-orient, self-guide and self-engage adisplay/control panel PCB 1834 in assembly with the front plate 1828, asillustrated in FIG. 145. As described elsewhere herein, the front plateincludes three integral spring ground clips 1836 formed thereon andextending forwardly thereof to resiliently engage correspondingcooperating grounding pads (not illustrated) on the PCB 1834. Refer FIG.96. In addition to ensuring that the PCB 1834 remains precisely spacedabove the outer surface 1826 of the closure member 1828 for componentclearance and cooling purposes, the split snap-catches 1830 and locatorpin standoffs 1833 effect reliable electrical connection of the PCBgrounding pads with exposed wire mesh suspended in the spring groundclips 1836. Refer FIG. 17.

Referring to FIG. 145, a subassembly 1838 depicts the closure member1828 of FIG. 144 in assembly with the PCB 1834. Split snap-catches 1830extend through registering openings 1840 in the PCB 1834 to secure thetwo components together. Similarly, the locator pins 1832 extend throughopenings 1842 in the PCB 1836 to ensure correct positioning thereof.

It is to be understood that the invention has been described withreference to specific embodiments and variations to provide the featuresand advantages previously described and that the embodiments aresusceptible of modification as will be apparent to those skilled in theart.

Furthermore, it is contemplated that many alternative, commoninexpensive materials can be employed to construct the basis constituentcomponents. Accordingly, the forgoing is not to be construed in alimiting sense.

The invention has been described in an illustrative manner, and it is tobe understood that the terminology, which has been used is intended tobe in the nature of words of description rather than of limitation.

Obviously, many modifications and variations of the present inventionare possible in light of the above teachings. For example, a number ofthe various radio/CD player case constructions illustrated herein areillustrated as being formed of solid molded polymer material for thesake of simplicity and clarity of understanding. It is to be understood,however, that the wire mesh depicted, for example in FIG. 93, can beemployed in the other configurations and embodiments with equal success.Furthermore, several of the housing assembly structures are describedherein as being formed of metal. However, a wide range of materialsubstitutes, including plastics, ceramics, non-ferrous metals andcomposites can be substituted without departing from the spirit andscope of the present invention. The terms “snap-engaging” and“self-engaging” are intended to interpreted very broadly inasmuch asinnumerable structural, process (e.g. weldments) and chemical (e.g.adhesives) equivalents are available. It is, therefore, to be understoodthat within the scope of the appended claims, wherein reference numeralsare merely for illustrative purposes and convenience and are not in anyway limiting, the invention, which is defined by the following claims asinterpreted according to the principles of patent law, including theDoctrine of Equivalents, may be practiced otherwise than is specificallydescribed.

The following documents are deemed to provide a fuller disclosure of theinventions described herein and the manner of making and using same.Accordingly, each of the below-listed documents are hereby incorporatedin the specification hereof by reference:

U.S. Pat. No. 6,384,355 B1 to M. Murphy et al. entitled “Parallel GuideMechanism for a Switch”.

U.S. Pat. No. 5,913,581 to F. Stephan et al. entitled “Integrated Slidesfor High Volume Production of Electronic Components”.

U.S. Pat. No. 5,784,254 to F. Stephan et al. entitled “Slide MountSpring-Clip Arrangement for Attaching an Electrical Component to aConvector”.

U.S. Pat. No. 6,054,647 to Ridener entitled “Grid Material forElectromagnetic Shielding”.

U.S. Pat. No. 4,685,563 to Cohen et al. entitled “Packaging Material andContainer having Interlaminate Shield and Method of Making Same”.

U.S. Pat. No. 5,061,341 to Kildal et al. entitled “Laser-Ablating aMarking in a Coating on Plastic Articles”.

U.S. Patent Application Publication No.: US 2006/0179446 A1 to Bickfordet al. entitled “Electrostatic Discharge Device and Method for MediaDevices”.

U.S. Pat. No. 6,663,250 to Rada et al. entitled “Integrated VehicleDisplay Lighting Assembly”.

U.S. Pat. No. 6,072,135 to O'Connor entitled “Self-Aligning ButtonRetainer”.

U.S. Pat. No. 7,021,811 B2 to Sylvester et al. entitled “LightDistribution Hub”.

U.S. Pat. No. 6,905,901 B1 to Fye et al. entitled “Method ofManufacturing a Cover of a Backlit Display Using Fluorescing Materials”.

U.S. Pat. No. 5,521,342 to Bartley et al. entitled “Switch HavingCombined Light Pipe and Printed Circuit Board”.

U.S. Patent Application Publication No.: US 2006/0250813 A1 to Lippmannet al. entitled “Illuminated Display System” and assigned to theassignee of the present application.

U.S. patent application Ser. No. 11/194,173 filed 1 Aug. 2005 to Snideret al. entitled “Display Apparatus”.

Audio Product Manual 04-RDPD-12-MA-F entitled “2004 Model Year FordFreestar Radios” (38 pages).

U.S. Pat. No. 7,180,745 B2 to Mandel et al. entitled “Flip Chip HeatSink Package and Method”.

U.S. Pat. No. 5,991,151 to Capriz entitled “Heat Sink, in Particular forElectronic Components”.

U.S. Pat. No. 4,683,359 to Wojtanek entitled “Illuminated SwitchAssembly with Combined Light and Light Shield”.

U.S. Pat. No. 5,727,675 to Leveque et al. entitled “Latching PushbuttonSwitch Assembly”.

U.S. Pat. No. 6,499,191 B1 to Howie, Jr. entitled “Knob with a CompositeLight Pipe having a Colored Face and a Light Pipe”.

U.S. Pat. No. 6,951,365 B2 to Chase et al. entitled “Flexible LampMounting”.

1. A method of fabricating an automotive audio system housing assemblyincluding a box-like case having wall portions and a front closuremember enclosing at least one audio component, said method comprisingthe steps of: forming a sheet of composite material comprising at leastone layer of relatively rigid polymer material and at least one layer ofelectrically conductive material capable of shielding said audiocomponent from electrical anomalies such as RFI (radio frequencyinterference), EMI (electromagnetic interference), BCI (bulk currentinjection), and ESD (electrostatic discharge); shaping a planer casepreform comprising a plurality of wall panels interconnected alongadjacent edges thereof by continuous living hinges formed at least byone of said constituent materials; providing a plurality of cooperatingengagement features affixed to said preform adjacent said wall paneledges; affixing said audio component to one of said preform wall panels;folding said preform panels at respective right angles to form saidcase; and affixing respective pairs of said engagement features toretain said case in a three-dimensional configuration.
 2. The method ofclaim 1, wherein said living hinges comprise composite layers of saidelectrically conductive material and said polymer material.
 3. Themethod of claim 2, further comprising the step of locallythinning/upsetting said layer of polymer material to define said livinghinge.
 4. The method of claim 1, wherein said engagement features areintegrally formed as part of said planer case preform.
 5. The method ofclaim 1, further comprising the step of affixing a heat sink to one ofsaid preform wall panels.
 6. The method of claim 1, further comprisingthe step of forming a discrete front plate closure member.
 7. The methodof claim 6, further comprising the step of interconnecting the frontclosure member to the case through an interconnecting audio component.8. The method of claim 1, further comprising the step of interconnectingat least two preform wall panels through an interconnecting audiocomponent.
 9. The method of claim 1, further comprising the step offorming ventilation and connector access openings within selectedpreform wall panels.
 10. The method of claim 1, further comprising thestep of die cutting said planer case preform from said composite sheetof polymer material and electrically conductive material.
 11. The methodof claim 1, wherein said step of forming said sheet comprises the stepsof: overlaying continuous sheets of said polymer material andelectrically conductive material; heating said overlayment of sheets toa temperature sufficient to affect bonding therebetwen; roll-firmingsaid overlayment of sheets to form a single composite structure; curingsaid single composite structure; die/punch cutting said compositestructure to form said case preform; and scribing/forming profiles ofsaid living hinge.
 12. The method of claim 1, wherein said step offorming said composite sheet comprises the step of fluidly extrudingsaid polymer material around a continuous sheet of electricallyconductive material.
 13. The method of claim 1, wherein said step offorming said sheet comprises injection molding said polymer materialaround a sheet of electrically conductive material.
 14. The method ofclaim 1, wherein said electrically conductive material comprises wirescreen.